Bulk Material Conveying
Power Plant Fly Ash Discharge and Conveying System
Rotary airlock discharge valves, drag chain conveyors and a bucket elevator replacing an open ash handling line that leaked dust into the boiler house.
Original condition
The problem on site
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.
Engineering approach
What we designed and built
- 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.
Measured results
Before and after commissioning
Values recorded on this project under its own operating condition. Results at another plant depend on fuel, material, load profile and the local standard in force.
| Item | Before | After |
|---|---|---|
| Conveying capacity | Frequent blockage at 25 t/h | 60 t/h stable operation |
| Dust leakage | Open trough spilling into the boiler house | Enclosed casing with airtight covers |
| Chain and flight wear | Replacement every 6 months | Hardened flights and liners extended service interval |
| Lifting height to silo | Manual transfer at intermediate level | 42 m bucket elevator direct to silo |
Outcome
How the system runs now
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.
Site records
Fabrication, erection and commissioning
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