Power Plant Fly Ash Discharge and Conveying System

Fly ash from the electrostatic precipitator hoppers was handled by an open trough conveyor. Dust leaked into the boiler house, the line blocked during humid weather, and chain wear forced a replacement every six months.

01Fitted rotary airlock discharge valves under each ESP hopper so ash feeds continuously while the system stays airtight.
02Replaced the open trough with enclosed drag chain conveyors in two lines, with hardened bottom liners and wear resistant flights.
03Added a 42 m bucket elevator with plate chain and backstop to lift ash directly to the storage silo.
04Used shaftless screw conveyors at dosing points where sticky ash had caused bridging.
05Installed level switches, speed monitoring and pull cord stops along the whole line for interlocked operation.

The ash handling line now runs enclosed at 60 t/h without the previous blockage during humid periods, and visible dust in the boiler house is eliminated. Wear parts service interval is extended by the hardened liners and flights, confirmed during the first planned inspection.