15th North American Waste to Energy Conference

May May 21-23, 2007, Miami, Florida USA

NAWLCT-3ZZ
DRY ASH COLLECTION AT COAL FIRED POWER PLANTS AND
POTENTIAL FOR W FACILITIES
Lead Author: Vincenzo Cianci
Research and Development Dep.
Magaldi Ricerche e Brevetti s.r.i., Salerno -ITALY
Via Irno 219 85134 Salerno - Italy
Co-author: Daniele Coppola
Magaldi Power s.p.a., Salerno -ITALY
Via Irno 219 85134 Salerno- Italy
Co-author: Werner Sunk
Earth Engineering Center,
Columbia University, New York, NY 10027
Summary
Remarkable environmental and economical benefits derive fom an innovative technology for dry bottom
ash removal fom coal-fred power plants that may be applied at WTE facilities combusting unprocessed
MSW or RF. This paper describes the MAC system technology that offers a very reliable and broadly
proved solution for dry bottom ash collection and handling. Up to now the MAC system has been installed
widely and successflly at coal-fred power stations. However, because of the fexibility of the MAC dry
ash collector and the wide experience of MAGALDI GROUP in conveying solid bulk materials, this
system is ready to be tested for the collection of bottom ash fom WTE boilers.
The MAC system concepts are discussed in detail as follows:

Description of various system confgurations;

Main diferences with traditional wet systems and principal advantages, emphasizing
environmental and economical aspects;

Evaluation of the main criteria for developing a new MAC system that can be applied in WTE
facilities.
In addition, an overview on the MAC reference facilities is presented with a closer examination of the
Fusina RDF cofred power plant (Venice, Italy).
1. Introduction
In Waste-To-Energy (WTE) power plant, the
bottom ash is typically discharged into a water
quenching tank. The water level provides a seal
and prevents ambient air fom entering the
combustion chamber. Also quenching the bottom
ash with water stops combustion immediately
and prevents fgitive emissions. However, one
of the disadvantages of quenching are the high
concentration of water in the ash (up to 30-40%
[3]) leading to unnecessary costs of transporting
and landflling water. Furthermore, the wet ash
tends to bind like cement and form accretions
41
that adhere on metals [4] thus lowering the value
of WTE metals and resulting in the loss of small
ferrous and non-ferrous metal pieces. Other
signifcant drawbacks of the wet systems consist
of lower boiler thermal efciency due to the high
unbured carbon content (UBC) in the bottom
ash. Dry ash extraction and processing is state of
the art technology at coal-fred power plants. The
main equipment is a totally enclosed reinforced
stainless steel belt conveyor that conveys the
discharged dry ash to the ash processing
equipment. Due to the processing of the ash in
dry state, the system allows for a more effcient
Copyright 2007 by ASME
screening of the ash [13] and separation of the
fine fraction 1 ) that is relatively high in
salts and other contaminants [4], thus increasing
the value of bottom ash for benefcial use outside
landfills.
Nevertheless, although these systems work in
many coalfred power plants all over the globe,
the feasibility of using such equipment at WTE
facilities needs to be tested. While power plants
use very homogeneous fels, the MSW fel in
WTE plants contains, if not processed in a RDF
plant, different materials in all particle sizes (e.
?
root stocks, bicycles, etc.). As some of these blg
chunks and materials do not bur completely or
are not combustible, they need to be processed
by the dry extraction system. Therefore, th

steel
belt conveyor must be designed so as to reslst the
impact of these big and heavy remaining chunks
and also to avoid failures due to jamming of
metallic objects between moving and fixed parts
(e.g. steel wires, etc.).
.
The frst occurrence has already been taken 1Oto
consideration in the dry system design by means
of the lateral off-set construction of the hoppers
in relation to the MAC systems that minmize the
fee fall distance of the ash and prevent direct
impacts on the belt conveyor. The fexibility of
the design of the dry ash collecting systems can
ensure that the conveyor can withstand such
impacts.
As the steel belt is enclosed within a sealed
casing that it is maintained at a negative press

re
with relation to the throat of the combustIOn
chamber, dust and emissions are drafed into the
boiler without the help of a fan. In addition, the
ambient air that is sucked into the enclosure acts
both as a cooling mediur and as tertiary air for
the oxidation of unbured carbon in the ash.
At this time, there is no major reason that will
inhibit the use of this system in the WTE
industr. With minor changes in design, the
MAC system and the downstream equipments
could be adapted to handle WTE bottom ash for
better contaminants reduction, material recovery
and beneficial use of the remaining bottom ash.
2. Description
Extraction
Power Plant
of the
System
Dry Bottom
at Coal-Fired
42
2.1. Etraction Belt
The MAGALDI Superbelt is the centerpiece of
the MAC extractor. It is a metal conveyer belt
made up of a stainless steel wire mesh belt
covered by overlapping stainless steel plates that
are arranged to form a continuous pan (Figure 1).
The belt is designed to withstand the arduous
operative conditions of dry bottom ash
conveying and the overload conditions at can
occur during the operations, such as the lmpacts
of big ash lumps that are occasionally dislodged
fom the walls of the combustion chamber.
The belt is driven by a drive pulley that transfers
the force by fiction (Figure 2). The ret d

at the tail section is equipped with an automatic
tensioning device to compensate for changes in
the length of the belt due to temperature
PAN
MESH -
`
HLcH
variations during operation.
Figure Z Section of Magaldi Superbelt
Figure Magaldi Superbelt
Copyright 2007 by ASME
The intennediate belt sections are equipped with
support and ret idlers. The belt runs
continuously undereath the boiler's throat,
receiving ash fom the face, at a speed that
can be adjusted fom few millimetres per second
up to 10 centimetres per second. The speed is set
up in order to keep the ash bed height at 1 cm at
the conveyer start and up to 10 cm at its end.
Furthennore, the speed of the belt conveyor
ensures a retention time for the ash of 8-10
minutes, to guarantee adequate cooling. As noted
earlier, the infltration of ambient air is
controlled to a minimum by enclosing the belt in
a sealed housing. A transition hopper is installed
between the belt and the boiler throat. The
bottom of the transition hopper is equipped with
doors that allow the MAC system to run also in
discontinuous mode and allow for minor
maintenance operations without the necessity to
shut down the boiler. Figure 3 shows the typical
cross sections of the MAC extraction belt. The
bottom of the MAC extractor is equipped with a
scraper chain conveyor (Figure 5) for removing
Figure MAC extractor: cross section (lef); side view (right)
43

Figure + Air inlets control scheme
the fine ash accretions from the belt to the
bottom of the casing.
2.2. Operation
During nonnal operation, the MAC system does
not require any personnel supervision. The belt
runs at a speed of few cms when the bottom
doors are open.
Figure J Spill chain view
Copyright 2007 by ASME
During conveying, the bottom ash is
progressively cooled and the UBC content is
reduced [ 7]. The cooling and post-combustion
efects are achieved by the countercurrent fow
of air that is drawn into the MAC system using
only the negative draf of the boiler (Figure 4).
The mass fow ratio between cooling air and ash
rate ranges fom 2. 5 to 3. 5, depending on the
actual needs. The amount of ambient air through
the MAC system at coal-fred power stations is
less than 1. 5%of the total amount of combustion
air. This quantity is controlled by pneumatically
actuated dumpers. Experimental tests verifed
that in a plant where the MAC system is installed
(Unit #4, Italy; plant owners: ENEL-Interpower)
the air fow through the MAC system did not
disturb the combustion process and nor affected
the rate of formation of NO _ [1].
2.3. System Downstream Configuration
As the ash is removed in a dry state, a variety of
conveying system arrangements are possible,
depending on the actual needs of the particular
facility:
1. Ash can be directly discharged fom the
MAC extractor into a removable storage
container through a double gate valve (this
method is recommended only for boilers with
limited ash production or when fnal ash
destination is uncertain).
2. A single crshing stage can be provided at
the extractor discharge to reduce the ash grain
size distribution. Aer sizing, the ash can be
dumped onto a mechanical conveyor heading
for a storage silo (Figure 6).
3. Afer the sizing by a primary crushing stage,
the bottom ash can be transported to a storage
silo by means of a pneumatic vacuum system
(this confguration is adopted in few cases [ 2]).
4.
Figure b - Confguration with single crushing stage
_ ao.--
g Bo!!o
vIves
_ Mechanicat
SEcd
_ MAC
et-oc!or
_ Pre-crusher _ secondory nechonica\
coveyor
@ e----,
c-os---
@ r|-c. s|.e
to pulverize the bottom ash before it is sent to
a silo. To accomplish this, a primary crusher is
used to initially size the material as it falls of
the extractor belt, then a secondary crusher
frther reduces the particle size of the bottom
ash to meet the requirements of the pneumatic
handling system. Therefore, the ash can be
conveyed by means of a pneumatic conveying
system to the fnal silo (Figure 7). A trial
operation showed that mixed fy and bottom
ash fom a coal fued power plant can be
reused as raw material for cement production
[ 6]. By mixing the ash its disposal is
simplifed as the combined ash is sent to the
same fnal destination (the cement industr).
This confguration has now been adopted by
Magaldi clients as the standard arrangement
for all fture bottom ash system retrofts.
3. MAC System Experience at the Fusina
RDF Co-Fired Plant
The latest improvements on the MAC systems
led to the possibility of operating the bottom ash
extractor at RDF co-fred boilers [11]. ENEL, the
owner and operator of the Fusina power station
(Venice, ITALY), has been operating the boilers
of the units #3 and #4 in co-combustion mode
with a coal-RDF fel mixture since 1998. The
amount of RDF that is co-fued represents about
2. 5%( 3. 5 t/h) of the total heat input of the boiler.
The operating conditions of the MAC system at
the belt level are not severe: the cooling air
temperature ranges from 200- 300C while the
ash temperature, where it is in contact with the
belt, is a little higher. Combustion of unbumed
particles in the bottom ash takes place in the
zone close to the boiler throat where the
conditions are much more favourable for
combustion reactions.
U Boiler
@ BetteM
vo|ves
44
Figure ^ Confguration with two crushing stages and
possibility of mixing fly and bottom ash
( Mechanical [] Pre-crusrer _ ln!ereo|u*e I] Secondary
5Eal tank crusher
[ MAC r Prllory I Secondary G rina! Silo
E)tractor crusher lEchonlcol
conveyor
Copyright 2007 by ASME
!00
30
60
0
b0
30
40
J
0
1

Figure - Laboratory tests on the UBC reduction

00b0m|rr00r||c05rH|0r0rrt|nrA0|1rrm|br0|rn;m00
!
2
2

--

/

1v T0 0
m8MtM0\|m0|rarta(m|a|
|
Z JU J0
I_Se 0mMRIP`J00"m0I0m0M|0N0" 8e NmMMJN000" '
Figure V - RF post-combustion in the MAC
extractor at the Fusina PP
The post-combustion at the Fusina power plant
(Figure 9) can be called "uncontrolled" since the
MAC system has been installed. In order to
move from the Magaldi Ash Cooler to the
Magaldi Ash Post-Combustor, two signifcant
constraints have to be taken into consideration:
1) Residence time;
2) Heat generation.
The presence of relatively large grains of
unbued material imposes a longer residence
time for a complete combustion of these
particles. Laboratory tests performed on bottom
ash derived fom the Fusina co-combustion
power plant have demonstrated the relation
between residence time and unbured conversion
at different temperatures (figure 8). The
laboratory tests showed that the minimal bed
temperature to activate the post-combustion of
RDF on the extractor is 400C. With a bed
temperature of 400C the reaction is mainly
controlled by difsive phenomena.
Following these studies, in order to control the
post-combustion temperature, inlet valves are
provided on both sides of the conveyor casing
(Figure 10) allowing the adjustment of the
amount of ambient air that enters the system.
The Fusina experience with RDF-fel has been
satisfactory for the MAC system, in terms of
increased boiler efciency and reliability of the
system [ 11]. Observations of the operating MAC
system have shown that only a thin layer of
molten RDF (mostly plastic particles) appears on
the belt which does not affect the performance of
the system (Figure 11). Unexpected post
combustion of RDF on the MAC conveyor belt
has not led to uncontrolled phenomena or
operating problems. Furthermore, it has been
observed that the molten RDF particles do not
Figure lU- Post-combustion air to improve post-combustion on the belt
PO5tcOmbu5\IOn
Ar
Loolng
Air
45
Copyright 2007 by ASME
clog the primary crusher rotor due to the
"cleaning action" of falling bottom ash.
4. Benefits of improving MAC Systems
at MSW-fired facilities
It is believed that dry bottom ash extraction and
processing at WTE facilities may result in
several environmental and economic benefts as
discussed below. However, it is not possible to
generalize the quantitative analysis of benefts
resulting fom the implementation of a dry
system. Depending on the actual situation of a
specific WTE facility some benefts can be more
signifcant than others.
4.1 Elimination of Water
We have observed at WTE facilities a make up
water consumption in the plunger ash extractor
with a water to ash mass ratio ranging fom 0.5
and 0.7. Part of this water is drawn into the
boiler due to evaporation and part of it is lost due
to the leakages of the water system. Also, a
significant amount of water is lost because the
water content (20-40%w) of the wet ash is
discharged by the plunger ash extractor The
elimination of water would yield to the following
direct benefts:

Water savings: for each ton of ash that is

handled by the extraction system we can
assume an average of 0.6 tons of water
that is now consumed by the wet system.
A dry ash system would save this amount
of water and could lower the costs of the
WTE facility's water consumption.

Cleaner working environment around the

ash system: eliminating water leakages
along the extraction line would prevent
the fation of puddles and dirty
locations. A cleaner working environment
is also a safer working environment.
Figure 11 - Molten RF on the Belt
46
Other signifcant indirect benefts achieved by
the elimination of water from the ash extraction
and processing system are taken into
consideration in the following paragraphs.
4.2. Ash Disposal and Reuse
Landflling unit costs are proportional to the total
weight of water and ash sent to disposal.
Elating an average content of 30% of water
in the ash allows lowering the disposal costs by
30%.
Furthermore, collecting bottom ash in a dry state
will result in higher quality of ash and the
recovered metals [13]. The absence of water
leads to a more efcient metal recovery process
fom the ash by the downstream equipments and
allows the separation of the minus I m faction
of bottom ash which has higher content of salts
and other contaminants [5]. In addition, the post
combustion on the belt in coal-fred power
plants reduces the UBC content of bottom ash
fom approx. 7 % by weight on average to less
then 1 %w [7]. The dry system valorises the
bottom ash and makes it a more attractive
material for different industries with lower
concentrations of UBC, contaminants and metal
residues. Thus, ash disposal costs can be saved
and could be tured into benefts for the WTE
facilities.
Figure 12 - Unbured carbon in bottom ash; tests at
Monfalcone PP, ENEL-Italy
UnbmMi C%
Arcnc
DSyim
A/at
4.3. Energy Savings Aspects
The adoption of a MAC dr ash handling system
on coal-fred boilers has led to increasing the
boiler efciency by recovering most of the heat
crossing the bottom opening of the boiler. This
heat is the sum of radiant fux fom the face,
sensible heat, and the chemical energy content of
ash that are lost in wet ash collection systems.
Copyright 2007 by ASME
Ta ble Then na l losses of wet a nd dry systems.
Overall data about Sines Power Station
Coal feed rate It/h) 115
13%
. ..
Ash content in coal
.... ... ....... .......... . ...... ....
Bottom ash 1 Fly ash split
Bottom ash feed rate
Global unit efciency
Thenal power losses [kW]
Radiation at boiler's throat
...-............ .....
Ash sensible heat
Radiation from external
rfCes

Ash chemical energy (UBC
content)*
Total
Savings with MA system
per unit [kW]
10% 190%
.......... .... .. ....... ...... .
g...a.. . .. !.
5 t
/
h
.
38%
Wet Dry
system system
691 0
~~=., ._
229 21
0 106
596 73
1516 200
1316
Figure l Then na l losses of wet a nd dry systems
\6
1+0

12

100

e
B

8
+00

200
CAsh ehemlc.lenerg(uoCcontlnt)
DRad!Uon from extemliaurfac
CAsh . nalbwMw t
Z3
DIherence
In tests performed at the Monfalcone facility,
one unit was equipped with a dry system and the
second with a wet system [12]. Samples from
both units were taken to make a comparison
between the UBC content in the discharged
bottom ash. Figure 12 shows the results of tests
conduced with two different types of coal, South
Afican coal which is difcult to bu and easy
to bu American coal: a reduction of 7 5% of
UBC was detected in both cases. The third series
47
of data shown in Fig. 1 2 relate to the average
value of UBC determined for all diferent coal
samples available for both wet and dry systems
and represents the typical performances of dry
and wet systems ( 5.7% UBC is determined for
the wet system, while only 0.8 % UBC remain in
the ash by operating a dr system).
Apar fom the possibility of post-combustion of
the UBC content in ash, the dry system allows to
recover the heat in form of radiant fux since the
metal conveyor almost thoroughly refects the
radiation back into the combustion chamber.
Furthermore, most of the ash enthalpy in the
form of sensible heat is recovered by the counter
current stream of cooling air and is drawn back
into the combustion chamber through the throat
of the boiler.
At the Sines coal-fred power plant (Portugal, 4
coal fred units, 314 electric output each),
where wet and dry systems coexist, energy losses
of both systems have been evaluated by
experimental and numerical tests. Table 1 and
Figure 13 s arize the results of this study.
The thermal power savings of 1316 kW
improved the Sines PP's boiler eftciency by
0. 20% on average.
At this time, there is no operating wet ash system
that has been replaced by a dry system at a WTE
facility but, on the basis of the Magaldi
experience and the WTERT information, a
hypothetical case is presented in Table 2 and
Figure 14 for a WTE unit combusting 35 tons
per hour.
Figure + Expected thenna l losses for a WTE fa cility
1200
10

80
m
o
m
m
S
seee
t
J
o

T
+eee
L
e
2000
021
CAsh et.miclenrg (USC cntent)
R_d"tion hm teral aur.ca
DAsh sensible hat
6875
Copyright 2007 by ASME
Table Z -Expected thermal power losses at a WTE unit
Overall data about a WTE unit
Fuel type MSW
' p?.(r.P. ''' ..
[
y ... . . .. ....... . . . . ..
Operating hours per year
. . ......,
LMV
[
kJ/kgj 9000
^'''1
35
Ash content in MSW-fuel 30%
B
Ct!C. " . .IX . .. p
lit
.................. . . Qr,,
Bottom ash feed rate 10 tlh
Thennal power losses [kY
Wet
system
Dry
system
Radiation at boiler's bottom
Cl1
i
I9 _ .
Ash sensible heat
Radiation from external
surfaces
180
0
1875
125
U
Ash chemical energy (U
B
C
6417
?^!l . .,,.............................. . . .. ....
Total 8472
Savings with MA system
[kY per unit
6407
106
1833
1958
Estzmated UbL content: /"for wet ash and z"
for dr ash.
The thennal power savings of 6407 kW would
increase the boiler effciency of the hypothetical
WTE unit by 7. 3 %. Assuming a fxed MSW
feed rate to the boiler and an effective operating
time of 8400 hours per year, this improvement
would increase the generation of electricity by
14. 7 GWh per unit and year on average or 44. 1
GWh per year for the whole plant ( 3 units).
From the above preliminary estimate, appears
that a significant improvement may be achieved
48
when buing a low quality solid fel (e.g.
MSW) than bung a better solid fel (e.g.
bituminous coal) [9]. This is due to the fact that
heat recovery fom the bottom ash of a WTE has
a much higher impact on thennal efciency than
for a coal fred boiler.
4.4. Maintenance, Reliability and Safety
Aspects
Further benefts can be achieved by the use of a
dry ash handling system in terms of lower
maintenance requirements. The absence of water
eliminates the erosioncorrosion problems
associated with the water handling circuit
(pumps and piping), the plunger ash extractor
and the bottom ash pit.
The MAC system has demonstrated very high
reliability. With more than 300,000 hours of
MAC systems operation, there has not been loss
of energy production in boilers equipped with
the MAC systems due to system failure or
malfnctions. As stated earlier, maintenance
activities can be perfonned with the system in
operation, without needing to shut down or
reduce the load of the boiler. Since the system
operates in a flly automatic mode, the risk of
hazards for personnel is negligible [8].
5. Reference Facilities
The MAC system has been installed over 70
times at coal-fred power plants worldwide.
Table 3 lists the most recent applications since
1999.
Copyright 2007 by ASME
Table 3 - MAC reference list since 1999
Plant - #Units Countr Owner Size

Start-up
Baoshan #2
People's Rep. Baoshan Iron & Steel Co.
350MW Retroft 2006
of China Ltd
......
_
- .... m__m ._---_ .... ...
Y onghung #3 #4 South Korea
Korea Easter Power Co. 2 x 87 0
New 2006
Ltd. MW

_
.
____

.._
.
.
....
_ .. - ._____________- . .....
I
Hadong #7 #8
.. _
Durgapur

=_.....
_

__
South Korea
India
_
_
.

_
_
.............
!s<g(12 ....

__..
*
JaEan
Baoshan #3
People's Rep.
of China
. ..

_......
Torrevaldaliga Nord
Italy
#2 #3#4
Abofo #2
_
_ .Eain
Baoshan #1
People's Rep.
of China
Sines #2 Portugal
Tean #7 #8 South Korea
Mindanao PhiliEEines

Kashima Japan

^^~=.
Sines F Port
ug
al
.-..

=
_ _
+
_
....... .. .
Calli de # 1 #2 Australia
--^~~
Jia Wang #3 #4
People's Rep.
of China
.... .a~~~
Datong #6
People's Rep.
of China
._,____.. _..____ . .
Memuro Japan
Mount Piper # 1 #2 Austalia
.... .............. . ......
Wallerawang #7 #8 Australia
....
Changchun # 1 #2
People's Rep.
of China
_._. __ ._-_.. _---_ ......
Fiumesanto #3 #4 Italy
Jia Wang #1 #2
People's Rep.
of China
__
.
__
_ _
. _.
Genova #9
H H
Los Barrios
...... .
Genova #5 #6 #7 #8
Tuopai #1#2
Iskenderun # 1 #2
Kobe #2
ydgos2cz #K3 F
Tomatoh-Atsuma #4
.
Kobe #1
Italy
S
E

._-.
Italy
People's Rep.
of China
__ HH ____ _ ____ H
Turkey
Jap
_
Poland
Japan
. ~~-=+m.....=.
Japan
Korea Easter Power Co.
Ltd.
The West Bengal Power
DeveloEment Co. Ltd.
J Power
Baoshan Iron & Steel Co.
Ltd
ENEL
HidroCantabrico
Baoshan Iron & Steel Co.
Ltd
CPPE
Korea Wester Power Co.
Ltd.
Steag State Power Inc.
Sumitomo Metal
Industries Ltd.
CPPE
CS Energy Ltd.
Jiangsu Provincial Electric
Power ComEany
SP Power Development
Co. Ltd.
Nippon Beet Sugar Mfg
Co.
Delta Electricity
Delta Electricity
Changchun Second Heat
& Power Co. Ltd.
Endesa Italia
Jiangsu Provincial Electric
Power ComEany
Enel
Endesa
Enel
Sichuan Tuopai Heat &
Power Ltd.
Iskenderun Eneri Uretim
Kobe Steel
ZesEol Elektro Bydgoszcz
Hokkaido Electric Power
Cor .
Kobe Steel
49
2 x 500
New 2005
MW
-................. _. __.........
300MW New 2005
.m _ .. _--
600MW New 2005
....... . __ .
__
. ..

__._-_
.
- ,... ,- __________ __ __
_

. _
350MW
3 x 660
MW
. .....
_
...
556MW
.._mm"._-----_ ...
350MW
314 MW
2 x 500
MW
_

._____.__..
105MW
507 MW
314 MW
2 x 350
MW
2 x 135
MW
200MW

._ .
.
........ ....
15MW
2 x 660
MW
2 x 500
MW
... ... _ .. .
2 x 200
MW
.-
____
.
___
__.
2 x 320
MW
Retroft 2005
New 2005
Retroft 2005
Retroft 2005
Retroft 2005
New 2004
New 2004
New 2004
Retrofit 2004
Retrofit 2004
New 2003
Retroft 2003
New 2003
.. __ .... .. ......-.-...-. .
Retroft 2003
Retrofit 2003
Retrofit 2003
Retroft 2003
--------.-.. -------.-
..
... m........ m.---... -..
2 x 135
New 2002
MW
_.H
160MW Retrofit 2002
_H____ HH H H._._ .
_
.
550MW Retroft 2002
4 x35 MW Retrofit 2001
.... _...... _
_
..___... .. .

..... _____
.
_
..
2x 7 5 MW New 2001
2 x 605
New 2001
MW
. =. _._--_ ._. __
_
.... .......... . .... .
7 00MW New 2000
65MW Retrofit 2000
. __............. ,=. , _.
__
- _+...... ..... HH_ ...
7 00MW New 1999
7 00MW New 1999
Copyright 2007 by ASME
6. Key-Criteria for Implementing the MAC
System in the WTE Industry
As the MAC dry ash handling system has been
widely installed on coal fred boilers but has just
one reference at a RF co-fred power plant, its
design development at WTE facilities has to be
carried on careflly in order to achieve the
expected dr system benefts rather than
unexpected problems by operating and manage
this system.
In order to ensure the project enhancement up to
its successflly industrial implementation at
WTE facilities, we recogize some key-criteria
in the dry ash handling system design as follows:
Cooling air fed rate: Because of the large
quantities of ash that need to be processed
by the dry extraction system and in order to
ensure the post-combustion of the UBC
content as well as the desired cooling effect,
a dr system at WTE facilities needs a
relevant amount of cooling air. Assuming
that for a single ton of processed ash the dry
system needs 2. 5 3. 5 tons of cooling air,
the cooling air needs for a typical WTE unit
( 35 t MSW, bottom ash 10 t on average)
would range between 25 to 35 tlh. Such an
air inlet from the bottom opening of a boiler
must be careflly evaluated in order to
ensure best possible conditions for
combustion in the boiler. It will be
considered to control the amount of air
drawn into the boiler through the MAC
system by the combustion air control system
(SYCOM) of the boiler.
Dusting: Large amounts of airbor particles
must be considered during discharging and
processing dry ash. A dusty environment
leads to higher costs in terms of cleaning
operations (a wet bottom ash processing area
is far from being a clean location) and a
higher health risk for employees as well as
people in the close neighbourhood must be
taken into consideration. The fne fraction of
ash from the combustion of MSW is indeed
higher in content of heavy metal salts and
other contaminants. Therefore, it is essential
to provide solutions against dust difsion.
In order to prevent dusting many solutions
could be installed such as dust aspirators in
the unloading areas, spraying nozzles for
low and controlled wetting of the ash, closed
casings for the ash processing equipment,
etc;
50
Engineers: The dry ash system is readily
adaptable to RF facilities and WTE that
pre-shred MSW and recover bulky metallic
objects before the feed enters the face,
such as the SEMASS process [16, 17].
7. Conclusion
At this time there is no major reason that
indicates that dry ash processing systems are not
feasible for the WTE industry. As dry ash
systems have been widely adopted at coal-fred
power plants, they could be adapted with minor
changes in design to handle WTE bottom ash
and ft with the downstream equipments for
contaminants reduction, material recovery and
benefcial use of the remaining bottom ash.
The presence of large objects in the bottom ash
of mass-bur plants (e.g. bicycles, unbued root
stocks, washing machines, etc.) will requie
some innovative thinking and collaboration
between Magaldi and WTE engineers. The dry
ash system is readily adaptable to RF facilities
and WTE that pre-shred MSW and recover bulky
metallic objects before the feed enters the
face, such as the SEMASS process.
Copyright 2007 by ASME
8. References
[I] E. Carrea, S. Orsino, J. Barsin, "Full Scale
Trias and Numerical Modelling of a Dry
Bottom Ash Extraction System fom a 330
MW Coal Fired Boiler", Proceedings of
Z Interational Joint Power
Generation Conference, Miami Beach,
Florida, July 23- 26, 2000;
[ 2] W. P. Reilly, J. Tomaszek, "New Design
Bottom Ash System at Cristal River Unit
no. 2", Edison Electric Institute Prime
Movers Committee Meeting Boiler
Subcommittee, Washington, D.C., October
24, 1994;
[ 3] W. Sunk, "Increasing the Quantity and
Quality of Metals Recovered at Waste-to
Energy Facilities", NA WTEC 14, Tampa,
FL, May 2006;
[4] "Trockenaustrag von KVA", Institut H
Umwelt- und Verfahrenstechnik, Jan
2006;
[ 5] R. Bunge, "The Incinerator of the Future:
an Omnivore for Municipal Waste",
ISWA, March 24th 2006 /NRI;
[ 6] R. Sorrenti, V. Quattrucci, M. Voltan,
"Dr Extraction and Recycling of Bottom
and Fly Ash, Costs Reduction and Better
Valorization of By Products", 2001;
[7] E. Carrea, M. Graziadio, "Bottom Ash
Carbon Content Reduction by Means of
MAC Dry Extraction System, a There
Project", Power Engineering
Interational, 1996;
[8] V. Cianci, "Risk evaluation on the tail
section of MAC", May Ith 2006;
[9] S. Vlachos, A. Carrea, "Dry Ash System
Retroft Improves Effciency of Unit at
Ptolemais Power Station", Power
Engineering Interational, May/June
1996;
[10] R. Tarli, M. Voltan, "Dry System
Improves ENEL Bottom Ash Handling",
Power Engineenring Interational, Nov
1993;
[II] B. Brozzi, R. Busatto, S. Malloggi, M.
Urbani, E. Dell' Andrea, G. Teardo, M.
Scala, "Centrale di Fusina: Esperienza di
Funzionamento in CoFiring CDR
Carbone sulle Unita 3 e 4", Termie
Project, 2006;
[12] V. Quattrucci, "The MAC System -
Dr Bottom Ash Extraction , Bulk Solids
51
Handling, Vol 17, Number 1,
January/March 1997;
[13] A. Selinger, V. Schmidt, "The ABB
Dry Ash Concept: INREC'', Waste
Materials in Construction: Putting Theory
into Practice, 1997 Elsevier Science B.V.
All rights reserved;
[ 14] United Authors, "Boiler Cleaning and
Ash Handling Systems", Steam: its
generation and use - Edition: 1 pp. 24.1
- 24. 21, 2005;
[15] United Authors, "Waste-To-Energy
Installations", Steam: its generation and
use-Edition: 1, pp. 29.1-29. 23, 2005;
[16] P. Estevez, "Management of Municipal
Solid Waste in Santiago, Chile: Assessing
Waste-to-Energy Possibilities", An
industrial Ecolog Study, Dec 9th 2003;
[17] Energy Answers Co., "Technology
Description and Performance History",
SEMASS Resource Recovery Facilit,
http:// .energyanswers.com/pdf/semas
s_tech_desc_and_perf_history.pdf.
9. Contacts

Vinceno Cianci, R&D Dept. - Magaldi

Ricerche e Brevetti s.r.l.
Via Iro 219,84135 Salero-Italy, Phone:
Phone: +39 089 688223,
vincenzo.cianci@magaldi.com;

Daniele Coppola, Sales Dept. - Magaldi

Power s.p.a.
Via lro 219, 84135 Salero-Italy, Phone:
Phone: +39 089 489248,
daniele.coppola@magaldi.com;

Werer Sunk, Industrial Environmental

Engineering, Columbia University
500 West 120th St., #926 Mudd Bldg,
New York, N.Y. 10027
Phone: +1 ( 212) 854-9136; Fax: +1 ( 212)
854-7 081; ws 217 2@colurbia.edu;

Mario Magaldi, Chairman - Magaldi

Group,

Via Imo 219, 84135 Salero-Italy, Phone:

Phone: +39 089 688268,
mario.magaldi@magaldi.com.
Copyright 2007 by ASME