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Various Ash Handling Systems
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DryBottomAshHandlingOptions&NewTechnology
WorldofCoalAshConference2009
2009 World of Coal Ash (WOCA) Conference - May 4-7, 2009 in Lexington, KY, USA http://ww.flyash.info/
EliminationofFlyAshfromAshPondsOptions&Advantagesp g
VacuumSystemtoSiloN h d i i ti i t k Nochangesunderprecip,usesexistingintakes
Limitonconveyingcapacityvs.distance
Dilute Pressure System to SiloDilutePressureSystemtoSilo MostPressureSystemsareDry
V /P T f S t t Sil Vacuum/PressureTransferSystemtoSilo Useexistingashintakes Nolimitonconveyingcapacityanddistance
DensePressuretoSilo Canreplacevacuumsystem Limitonconveyingcapacityanddistance
DryFlyAshConveyingDilute/DenseFlowRegimesg
DryFlyAshConveyingCapacityvs.Distancep y
DryFlyAshConveyingVacuumSystemtoSiloy
DryFlyAshConveyingPressureSystem MostAlreadyDryy y y
DryFlyAshConveyingVacuum/PressureTransferStation
DryFlyAshConveyingVacuum/PressureTransferStation
DryFlyAshConveyingEnclosedVacuum/PressureTransferStation
DryFlyAshConveyingVacuum/PressureTransferSilo
DryFlyAshConveyingVacuum/PressureTransferSiloInstallation
DryFlyAshConveyingPressureFeedersUnderTransferSilo
DryFlyAshConveyingPressureFeedersUnderTransferSilo
DryFlyAshConveyingPressureLinetoRemoteSilo
DryFlyAshDensePhasePressure CanReplaceVacuumSystemp y
15
DryBottomAshConveying
1940s1950s:UCCdevelopsdrybottomashconveying
withNUVEYOR pneumaticashconveyingsystems,gravitydischargeashpitg y g phoppers.
RenditionofaUCCNUVEYORsystemforautilityboiler,includinggravitydischargeashpithopper.
DryBottomAshConveyingTemperaturep
DryBottomAshConveyingSlagFallsg
EliminationofBottomAshfromAshPondsOptions&Advantagesp g
ReCirculatingWaterSystem No changes under boiler uses existing hopper Nochangesunderboiler,usesexistinghopper Switchtonewsystemin3dayoutage
SubmergedFlightConveyor SFCg g y Mosteconomicalchoice Simplesolutionifspaceisavailable
i C i DryHopperPneumaticConveying PAX Nowater,returnsheatbacktoboiler Easiest100%dryoptiontogetoutofboilerbuilding
VibratoryConveying VAX Nowater,returnsthemostheatbacktoboiler Continuousremovalofbottomash
DryBottomAsh ReCirculationSystem
DryBottomAsh ReCirculationSystem
DryBottomAsh SFC
DryBottomAsh SFC
DryBottomAsh SFC
DryBottomAsh PAXSystem
DryBottomAsh PAXSystem
DryBottomAsh VAX
DryBottomAsh VAX
DryBottomAsh VAX
DryBottomAshFeaturesComparisonp
ReCircTanks SFC PAX VAX
CostsDesignandmaterialCosts $5M $2M $3.5M $3.5M
CostsInstallationCost $4.5M $1.5M $3.5M $2.5M
PreOutageConstruction6 months 2 months 2 months 2 months
OutageRequirement
Duration6months 2months 2months 2months
OutageConstruction 3days 3weeks 8weeks 6weeks
OutageStartUp 2 3days 1 2days 3 4days 1 2days
LeadTime 9months 9months 12months 12months
DryBottomAshFeaturesComparisonp
Re Circ Tanks SFC PAX VAXReCircTanks SFC PAX VAX
YardPipingCorridor Yes No Yes No
Boiler&YardSpaceBoilerHouseExitCorridorforMechanicalConveyor
No Yes No Yes
YardFootPrint 6500sqft 1500sqft 1500sqft 1000sqft
Storage Bin Serves moreMultipleUnitsynergies
StorageBinServesmorethanoneboiler
Yes No Yes No
DryBottomAshFeaturesComparisonp
RecircTanks SFC PAX VAX
HighPressurePumps Yes No No No
Vacuum/PressureBlowers
No No Yes No
O ti d M i t
Refractory Yes existingUsuallynone
YesUsuallynone
Yes OperationsandMaintenanceCosts
ConveyorChainReplacement
No Yes NoYes
SecondaryConveyor
CrushersYes existing
(3)Usuallynone
Yes(3) Yes(1)
ConveyingConveyingpipeline/valves
Yes No Yes No
DryBottomAshFeaturesComparison
Re Circ Tanks SFC PAX VAX
p
ReCircTanks SFC PAX VAX
Makeupwater 100gpm 50gpm None None
Cooling Water 400 gpm 400 gpm None NoneWaterConsumption
CoolingWater 400gpm 400gpm None None
ConveyingWater(recirculating)
2500gpm None None None
Power Consumption
Pumps 600HP 50HP None None
Blowers/Fans None None 200 HP 50 HPPowerConsumption Blowers/Fans None None 200HP 50HP
MechanicalDrives 50HP 100HP 50HP 75HP
DryBottomAshDecisionAnalysis
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
DecisionAnalysisFavorsReCirculationSystem
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
DecisionAnalysisFavorsSFCSystem
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
DecisionAnalysisFavorsPAXSystem
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
DecisionAnalysisFavorsVAXSystem
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
PreAssemblyOptions
PreAssemblyOptions
PreAssemblyOptions
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