Dry Bottom Ash Handling Options and New · PDF fileDry Bottom Ash Handling Options & New...
Transcript of Dry Bottom Ash Handling Options and New · PDF fileDry Bottom Ash Handling Options & New...
Dry Bottom Ash HandlingOptions & New Technology
World of Coal Ash Conference 2009
2009 World of Coal Ash (WOCA) Conference - May 4-7, 2009 in Lexington, KY, USA http://ww.flyash.info/
Elimination of Fly Ash from Ash Ponds –Options & Advantagesp g
• Vacuum System to SiloN h d i i ti i t k• No changes under precip, uses existing intakes
• Limit on conveying capacity vs. distance
• Dilute Pressure System to SiloDilute Pressure System to Silo• Most Pressure Systems are “Dry”
V /P T f S t t Sil• Vacuum/Pressure Transfer System to Silo• Use existing ash intakes• No limit on conveying capacity and distance
• Dense Pressure to Silo• Can replace vacuum system• Limit on conveying capacity and distance
Dry Fly Ash Conveying –Dilute/Dense Flow Regimes g
Dry Fly Ash Conveying –Capacity vs. Distance p y
Dry Fly Ash Conveying –Vacuum System to Siloy
Dry Fly Ash Conveying –Pressure System – Most Already Dry y y y
Dry Fly Ash Conveying –Vacuum/Pressure Transfer Station
Dry Fly Ash Conveying –Vacuum/Pressure Transfer Station
Dry Fly Ash Conveying –Enclosed Vacuum/Pressure Transfer Station
Dry Fly Ash Conveying –Vacuum/Pressure Transfer Silo
Dry Fly Ash Conveying‐Vacuum/Pressure Transfer Silo Installation
Dry Fly Ash Conveying –Pressure Feeders Under Transfer Silo
Dry Fly Ash Conveying –Pressure Feeders Under Transfer Silo
Dry Fly Ash Conveying –Pressure Line to Remote Silo
Dry Fly Ash –Dense Phase Pressure – Can Replace Vacuum Systemp y
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Dry Bottom Ash Conveying
1940’s‐1950’s: UCC develops dry bottom ash conveying
®with NUVEYOR® pneumatic ash conveying systems, gravity discharge ash pit g y g phoppers.
Rendition of a UCC NUVEYOR system for a utility boiler, including gravity discharge ash pit hopper.
Dry Bottom Ash Conveying –Temperature p
Dry Bottom Ash Conveying –Slag Falls g
Elimination of Bottom Ash from Ash Ponds –Options & Advantagesp g
• Re‐Circulating Water System• No changes under boiler uses existing hopper• No changes under boiler, uses existing hopper• Switch to new system in 3 day outage
• Submerged Flight Conveyor – SFCg g y• Most economical choice• Simple solution if space is available
i C i• Dry Hopper Pneumatic Conveying – PAX• No water, returns heat back to boiler• Easiest 100% dry option to get out of boiler building
• Vibratory Conveying – VAX• No water, returns the most heat back to boiler• Continuous removal of bottom ash
Dry Bottom Ash – Re‐Circulation System
Dry Bottom Ash – Re‐Circulation System
Dry Bottom Ash ‐ SFC
Dry Bottom Ash ‐ SFC
Dry Bottom Ash ‐ SFC
Dry Bottom Ash ‐ PAX System
Dry Bottom Ash ‐ PAX System
Dry Bottom Ash ‐ VAX
Dry Bottom Ash ‐ VAX
Dry Bottom Ash ‐ VAX
Dry Bottom Ash –Features Comparisonp
Re‐Circ Tanks SFC PAX VAX
CostsDesign and material Costs $5 M $2 M $3.5 M $3.5 M
CostsInstallation Cost $4.5 M $1.5 M $3.5 M $2.5 M
Pre‐Outage Construction 6 months 2 months 2 months 2 months
Outage Requirement
Duration6 months 2 months 2 months 2 months
Outage Construction 3 days 3 weeks 8 weeks 6 weeks
Outage Start‐Up 2 ‐ 3 days 1 ‐ 2 days 3 ‐ 4 days 1 ‐ 2 days
Lead Time 9 months 9 months 12 months 12 months
Dry Bottom Ash –Features Comparisonp
Re Circ Tanks SFC PAX VAXRe‐Circ Tanks SFC PAX VAX
Yard Piping Corridor Yes No Yes No
Boiler & Yard SpaceBoiler House Exit Corridor for Mechanical Conveyor
No Yes No Yes
Yard Foot Print 6500 sq ft 1500 sq ft 1500 sq ft 1000 sq ft
Storage Bin Serves moreMultiple Unit synergies
Storage Bin Serves more than one boiler
Yes No Yes No
Dry Bottom Ash –Features Comparisonp
Re‐circ Tanks SFC PAX VAX
High Pressure Pumps Yes No No No
Vacuum/Pressure Blowers
No No Yes No
O ti d M i t
Refractory Yes ‐ existingUsually none
YesUsually none
Yes ‐Operations and Maintenance Costs
Conveyor Chain Replacement
No Yes NoYes
Secondary Conveyor
CrushersYes ‐ existing
(3)Usually none
Yes (3) Yes (1)
ConveyingConveying pipeline/valves
Yes No Yes No
Dry Bottom Ash –Features Comparison
Re Circ Tanks SFC PAX VAX
p
Re‐Circ Tanks SFC PAX VAX
Make‐up water 100 gpm 50 gpm None None
Cooling Water 400 gpm 400 gpm None NoneWater Consumption
Cooling Water 400 gpm 400 gpm None None
Conveying Water (re‐circulating)
2500 gpm None None None
Power Consumption
Pumps 600 HP 50 HP None None
Blowers/Fans None None 200 HP 50 HPPower Consumption Blowers/Fans None None 200 HP 50 HP
Mechanical Drives 50 HP 100 HP 50 HP 75 HP
Dry Bottom Ash Decision Analysis
Technology AlternativesTechnology Alternatives
1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX
Criteria for Determing Technology Selection WT SC Total SC Total SC Total SC Total
Water Usage/Availability 0 2 0 3 0 5 0 5 0Outage Time Available 0 5 0 4 0 2 0 3 0Total Installed Cost 0 1 0 5 0 3 0 3 0Total Installed Cost 0 1 0 5 0 3 0 3 0Operation & Maintenance Cost 0 2 0 5 0 3 0 4 0Power Consumption 0 1 0 4 0 2 0 5 0Boiler House Corridor Availability 0 5 0 3 0 5 0 3 0Boiler House Corridor Availability 0 5 0 3 0 5 0 3 0Multiple Unit Synergies 0 5 0 2 0 4 0 2 0
Weighted Total Score 0 0 0 0
Decision Analysis Favors Re‐Circulation System
Technology AlternativesTechnology Alternatives
1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX
Criteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC Totalg gy
Water Usage/Availability 2 2 4 3 6 5 10 5 10Outage Time Available 5 5 25 4 20 2 10 3 15Total Installed CostTotal Installed Cost 2 1 2 5 10 3 6 3 6Operation & Maintenance Cost 2 2 4 5 10 3 6 4 8Power Consumption 2 1 2 4 8 2 4 5 10Boiler House Corridor Availability 5 5 25 3 15 5 25 3 15Boiler House Corridor Availability 5 5 25 3 15 5 25 3 15Multiple Unit Synergies 5 5 25 2 10 4 20 2 10
Weighted Total Score 87 79 81 74
Decision Analysis Favors SFC System
Technology AlternativesTechnology Alternatives
1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX
Criteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC Total
Water Usage/Availability 4 2 8 3 12 5 20 5 20Outage Time Available 5 5 25 4 20 2 10 3 15Total Installed CostTotal Installed Cost 4 1 4 5 20 3 12 3 12Operation & Maintenance Cost 3 2 6 5 15 3 9 4 12Power Consumption 2 1 2 4 8 2 4 5 10Boiler Ho se Corridor A ailabilitBoiler House Corridor Availability 1 5 5 3 3 5 5 3 3Multiple Unit Synergies 1 5 5 2 2 4 4 2 2
Weighted Total Score 55 80 64 74
Decision Analysis Favors PAX System
Technology AlternativesTechnology Alternatives
1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX
Criteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC Totalg gy
Water Usage/Availability 5 2 10 3 15 5 25 5 25Outage Time Available 1 5 5 4 4 2 2 3 3T t l I t ll d C tTotal Installed Cost 3 1 3 5 15 3 9 3 9Operation & Maintenance Cost 3 2 6 5 15 3 9 4 12Power Consumption 3 1 3 4 12 2 6 5 15Boiler House Corridor Availability 5 5 25 3 15 5 25 3 15Multiple Unit Synergies 5 5 25 2 10 4 20 2 10
Weighted Total Score 77 86 96 89
Decision Analysis Favors VAX System
T h l Alt tiTechnology Alternatives
1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX
Criteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC TotalCriteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC Total
Water Usage/Availability 5 2 10 3 15 5 25 5 25Outage Time Available 1 5 5 4 4 2 2 3 3Total Installed Cost 3 1 3 5 15 3 9 3 9Operation & Maintenance Cost 3 2 6 5 15 3 9 4 12Power Consumption 5 1 5 4 20 2 10 5 25Boiler House Corridor Availability 2 5 10 3 6 5 10 3 6Multiple Unit Synergies 1 5 5 2 2 4 4 2 2
Weighted Total Score 44 77 69 82
Pre‐Assembly Options
Pre‐Assembly Options
Pre‐Assembly Options
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