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In a modern, pulverized-coal burning boiler, the ash steam generators has increased,ash handling systems
handlingsystemnormallycollects,transportsand stores have also grown in capacity. Increasedenviron-
all of the solid by-productsof the combustionprocess. mental awarenesshas also caused major changes in
Thesetypically include: ash handling techniques. Among the most notable are
the use of sophisticated air filtration equipment
. Bottom ash: the materialthat falls to the bottom in pneumatic systemsand the increased use of closed
of the boiler; possibly a heavyslag. loop recirculating hydraulic systems to constantly
. Economizerand air heaterash:the coarse recycle conveying water.
particles in the flue gas which drop out when
the gas stream changesdirection.
. Fly ash:the fine ash particles in the gas stream
which are removedby the dust collection
equipment.
. Mill rejects:the coarse, heavypiecesof stone,
slate and iron pyrites dischargedfrom the coal
pulverizer.
An ash handling system must collect and transport
large quantities of hot, extremely abrasivematerial.And
it must do so reliably and efficiently. Successfully
meetingthese requirementsdemandsa broad spec-
trum of expertiseencompassingmaterialsengineering,
equipment design and systemsintegration.
Since Allen-Sherman-Hoff began supplying ash
handling systemsto electric utilities in 1917,the
technology has advanced dramatically. As the size of

. Mill Rejects Bottom Ash

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Because of the high furnace temperatures of pulverized incorporates full closed cycle water recirculation and
coal fired boilers, bottom ash must be water quenched dewatering bins to drain water from the accumulated
as it is collected. Consequently, most utility plants in the ash. Here, after passing through the dual roll clinker
United States have used hydraulic conveying of bottom grinders, the ash is pumped by centrifugal slurry pumps
ash, although submerged mechanical drag conveying is to A-S-H Hydrobin@ dewatering bins. Two Hydrobins are
gaining in popularity. required for each system. One receives ash slurry while
The system in diagram 1 illustrates a basic hydraulic the other is draining or decanting. The dewatered ash
conveying technique where bottom ash falls from the is discharged from the bottom of the bin directly into
boiler into a water-filled ash hopper. Normal design trucks or railcars for off-site disposal. Each Hydrobin
criteria suggests 12 hours of storage in the ash hopper. is normally sized for 36 hour storage, with the combined
This provides a convenient procedure where ash is total of 72 hours providing adequate capacity for long
transported once during each eight hour shift. From weekends when truck or rail service is not available.
the hopper, the ash passes through a large gate and From the dewatering bins, the decanted water flows
into dual roll clinker grinders which reduce clinkers to by gravity into a settling tank to remove fines and
an appropriate size and feed the ash to a hydraulic ejector. carry-over, and then into a surge or storage tank. Sludge
The resultant ash-water slurry is pumped to a large pumps under the settling and surge tanks return any
retaining pond. Make-up water, seal water and impulse settled ash back to the dewatering bin. Recirculation
water are supplied by medium and high pressure pumps return the water for reuse in the system.
centrifugal pumps. Once considered the basic bottom The full recirculation system has the advantage of
ash conveying method, these systems are now limited requiring little make-up water, little land area and it
by environmental restraints, the need for large land produces a relatively dry ash (about 15% water by weight)
areas for settling/retention ponds, and lack of easy to transport by rail or truck. Also, there is no water
abundant water supplies. discharged into streams or rivers.
A more modern practice is shown in diagram 2. This

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Bottom ash collection. In conventional systems, bottom the ash slurry and then drain or decant the conveying
ash dropping out of the furnace is collected in a water from the solid material. Two dewatering bins are
water-impounded hopper installed directly under the used in each installation, one to receive ash while the
boiler. Depending on the particular boiler, fuel and other is dewatering or on standby.
plant configuration, the hopper may have one, or Initially, the Hydrobin is partially filled with water.
Incoming ash slurry is discharged into the center of the
more pant legs.
An independent water-filled seal trough surrounds Hydrobin where a bar screen classifier diverts coarser
the boiler seal plate, which provides an atmospheric material to the sides of the bin while finer particles drop
seal to the furnace, and allows for expansion of the into the center. The coarser particles then act as a filter
boiler. A continuous curtain of cooling water flows to trap fines before they reach the decanting elements.
over the refractory lining of the hopper. An underflow baffle directs all incoming material
Allen-Sherman-Hoffbottom ash hoppers are designed downward and helps to prevent the fines from reaching
with sloped sides to permit ash to enter the conveying the overflow baffle. When the bin fills, the water overflows
system at high rates. The hoppers also normally include a serrated weir. This weir is used to insure a uniform
inspection windows, access doors and lancing doors flow pattern and to simplify leveling during construction.
to accommodate individual requirements.
Mounted on the sloping side of each pant leg is an
integral discharge gate and housing assembly.The gate
forms a seal when closed and is hydraulically opened
for feeding ash into the conveying system. The housing
is provided with both vacuum and pressure relief
equipment.
Bottom ash conveying. Double-roll clinker grinders
at each disqharge.gatesize all ash clinkers and slag into
small particles for conveying. A-S-H grinder rolls are
constructed of manganesesteel, with integrally cast
teeth, for durability.
From the grinders, the sized ash passesinto a piping
system for transportation to disposal or storage. The
motive force can be supplied either by an A-S-H
Hydro-EjectorTMjetpump or a centrifugal slurry pump.
The choice between the two types of pumps is a factor
of plant layout, required conveying rates, distances and
the specific gravity of the particular ash being handled.
In Allen-Sherman-Hoff systems,the ash slurry is
normally transported through Ashcolite@pipe, a hard
iron alloy pipewith uniformwall thicknessand dense,
close grained structure. The plain-ended Ashcolite
pipe is assembledwith sleeve couplings, eliminating
the need to fabricate and stock odd lengths. Fittings
have integral wear backs, with maximum thickness
in the area of greatest wear. Alternate pipe materials,
such as ceramic-lined fiberglass reinforced pipe, are
also available.
Knife-gate AshfloTM valves are used for isolation and
shut-off. In the open position, the valve gate is retracted
completely out of the flow path of the erosiveash slurry.
Bottom ash disposal. Hydrobin@dewatering bins receive~

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Once the bin has received its load of ash, an upper,
floating decanter rapidly drains the standing water
above the ash down to the level of solid material. This fea-
ture eliminates the tendency for the hydraulic head to
force fines through the stationary decanting elements.
The floating element, in combination with the stationary
lower decanting screens and valves, allow the
Hydrobin to dewater the ash to a commercially dry state
(approximately 15% water by weight). Once dewatering,is
complete, ash is discharged easily and quickly through
a wide, horizontal bottom opening gate into trucks or
rail cars for disposal, The A-S-H Hydrobin discharge
gate is provided with heating elements to prevent
freeze up, vibrators to clean the side walls, and
air-operated seal tube to prevent water leakage.
Mechanical drag conveying of bottom ash has been the ash is compacted ahead of the bars. This compaction,
used extensively in Europe. This technology offers plus gravity, dewaters the ash and the excess water
~everal advantages, including lower operating costs drains back into the wet trough. At the end of the incline,
and the need for less clearance under the boiler. However, the ash is relatively dry and is discharged into one
drag units are susceptible to damage from slag falls or more of a series of drag or belt conveyors to a storage
accounting for their popularity in installations or dewatering bin.
burning non-slagging fuels. Because of the inherent Normally, ash removal from the boiler is continuous,
advantages of the drag technology, Allen-Sherman- but the availability of truck and railcars requires a
Hoff has adopted, and improved upon, many of the storage bin with a capacity of three days. The storage
features of proven European designs and incorporated bin may be equipped with decanting elements to drain
them into an original system designed for the ash and excess retained water from the ash during storage and
slagging characteristics of various fuels. r:eturn the decanted water back to the submerged system.
During operation, bottom ash falls through a transition The water recirculation includes a continuous flow of
chute or retention hopper into the water trough of the water into and out of the submerged trough to maintain
conveyor. The chute or hopper includes a seal trough to a bath temperature appropriate for quenching the ash.
provide a seal against the boiler pressure and the sloped Overflow water from the trough is filtered in tanks or
sides direct the fall of slag and ash into the center of gravity settlers before it is recirculated back to the
the conveyor. Upon entering the wet trough, the ash is system. Since the system is continuous, surge tanks
picked up by the flight bars and moved toward the are comparatively small. Make-up water is only needed
dewatering incline. to replace retained water discharged with the ash, and
As the flight bars move up the dewatering incline, the minimal amounts lost through evaporation.

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Most of the solid residue from a pulverized coal boiler At the silo, various arrangements of dust collectors
is carried away by the flue gas. Coarser particles will separate the fly ash from the conveying air. The most
drop out of the gas stream at changes in direction such common arrangement uses a cyclone collector as
as in the economizer and air preheater. However, the the primary separation device with a combination
largest volume of ash in today's power plants is composed cyclone/bag filter for secondary collection. The primary
of fine particles of fly ash removed by the air cleaning collector is equipped with separate chambers so it can
devices - precipitators or baghouses. operate continuously, feeding ash into the silo while
Because fine particles do not settle out of suspension the top of the collector is still under vacuum. The bag
easily, fly ash is almost always collected and transported filter may be continuous or intermittent. With the
pneumatically rather than hydraulically. Depending on intermittent arrangement, the system is shut
site-specific considerations, these systems generally down periodically and the bag house storage hopper is
fall into one of three general types. discharged into the silo. In either arrangement the
. Vacuum. Pressure .Combination Vacuum/Pressure bags are continuously cleaned by pulse jet action.
Air preheater ash is generally handled as part of these
systems.
Vacuum systems. Vacuum conveying generally provides
the lowest initial cost for a fly ash system. In addition,
the headroom required under the fly ash hoppers is
minimized and operation is somewhat cleaner since
any leaks are into the system. However, vacuum systems
provide limited conveying capacities and distances.
The conveying vacuum can be produced either
hydraulically (with a Hydrovactorl@>jet exhauster) or
mechanically (by a vacuum pump). Collection and
filtration equipment are located on the silo roof. Even
with this filtration equipment, some residual ash passes
through the vacuum producer. Dry mechanical vacuum
pumps simplify venting systems and do not produce
waste fluids.
In a vacuum system, each pickup point is equipped
with a materials handling valve and air inlets to smoothly
feed ash into the conveying line. The system is normally
arranged into branches, with each branch containing
a number of pickup points. Automatically controlled
segregating valves isolate each branch line, allowing
each to be activated independently. Air inlet check
valves at the heads of the branch lines provide additional
conveying air.

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Pressure systems. Pressurized conveying of fly ash of three sequential operations. Initially both gates in
offers some definite advantages over vacuum systems. the valve are closed (a) and the pressure of the
Pressurized systems provide greater capacity, can primary chamber is equalized with that of the overhead
convey over longer distances, and simplify the dust/air hopper. Then the gate valve above the primary chamber
separation equipment needed at the silo. Because the (b) is opened for a preset period of time. This dwell time
feeding device at each pickup point is larger, allows a measured amount of fly ash to flow by gravity
pressure systems require more headroom under each into the primary chamber. At the end of the loading
hopper and have a higher initial cost in installations cycle the upper gate valve closes to isolate the chamber
with a multitude of collection points. However, their from the hopper. The upper chamber is pressurized
operational costs are often less than a vacuum system's to a level slightly greater than the conveying line
if conveying distances are much over 500 feet. (50m). pressure and when the lower gate opens (c), ash is forced
Positive displacement blowers provide the air flow down into the conveying line through an intake tee
and pressure for conveying the fly ash. Allen-Sherman- that imparts a swirl to the ash for better pick
Hoff airlock valves allow the fly ash to be transferred up performance.
from the collection hopper into the pressurized conveying Automatic butterfly valves at the heads of the branch
pipe. lines provide branch isolation while manually
The airlock valve transfers fly ash into the pressurized operated knife gate valves at the ends of the branch
conveying pipe, while preventing backflow by means lines serve as maintenance cut off valves.

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Combination vacuum/pressure systems. Sometimes
a combination system is most practical since it uses
a materials handling valve at each collection point but
can transport over much longer distances than a
conventional vacuum system.
The fly ash is transported to an intermediate vacuum/
pressure transfer station, which has the same basic
collection equipment as used on the vacuum system silo.
I n dilute phase systems, the transfer station can have
either a compact vacuum/pressure transfer tank or a
surge bin which also provides intermediate storage.
The vacuum/pressure transfer tank transfers ash
between unequal pressure zones and is the primary
ash/air separation device. Each tank has three chambers,
separated by dump gate valves. In addition, the top
chamber includes a cyclone collector.
With the top gate open and the bottom gate closed, fly
ash drops into the middle chamber. Periodically, the
separatedfrom the conveying vacuum just as in a
conventional vacuum system.The surge bin is equipped
Fly ash
with one or more airlock valves which feed the fly ash
into the pressurizedconveying line. The surge bin allows

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hoppers
Materials the pressuresystem to have a lower conveying capacity
handling than is neededwith the transfer tank system. This may
~ valve
lower operation costs.
Vscl!l!m line Dense-phasepressureconveying can also be used by
equipping each storage bin with a pair of Allen-
Fabric filter

VACUUM-PRESSURE
SYSTEM-TRANSFER
TANK
Vacuum

.
pump
Pressure
blower
I
. Pressure line

upper gate is closed and the middle chamber is


pressurized to slightly above the conveying line pressure.
Now the lower gate opens, and fly ash falls into
the bottom chamber. When the bottom gate is closed, the
pressure in the middle chamber is equalized to the
the vacuum system, and the top gate reopens for another
cycle. Material from the bottom chamber is continuously
fed into the transport piping. Sherman-Hoff Fluidizing Transporters.
The vacuum line from the transfer tank discharges Because the transporters fluidize the ash, they convey
into a secondary collector, which includes a bag filter. large amounts of ash with less air and at a lower velocity
Normally this collector has an airlock valve and is than dilute phase systems. The higher capacity
discharged into the pressurized conveying line at usually allows smaller conveying pipe and the lower
appropriate intervals. velocity often allows the use of standard piping
A second transfer method uses a surge bin. Ash is materials.

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Fly ash storage silos are an integral part of the fly ash
handling system, and their design is predicated on the
overall system dynamics including the conveying,
venting, aerating, and unloading subsystems. The silo
system is normally designed to accommodate a 3-day
storage capacity. Since Allen-Sherman-Hoff dry
unloaders provide for displaced air to be vented back
to the silo, the silo vent system must be sized to handle
this volume, in addition to conveying and displaced
air. The vent itself may be either a bag filter, or vent fans
to exhaust air back into the precipitator (or baghouse)
inlet breeching.
Other design parameters include the aeration stone
geometry (and the venting of this aeration air), clearance
beneath the silo floor for rail or truck access, wind and
seismic considerations. If fly ash is to be discharged
into open trucks, A-S-H dust conditioner/unloaders will
be supplied to continuously feed and moisten the
discharged ash.

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The coarser ash in the gas stream which falls out under
the economizer may be handled in a number of different
ways depending on the overall system configuration.
One method is to handle this ash hydraulically and
discharge it into the Hydrobin@ dewatering bin along
with the bottom ash and mill rejects. But some types of
economizer ash are difficult to decant or remove
from the conveying water, and a more usual technique
is to include economizer ash collection as part of the
fly ash sytem and handle it pneumatically. In this case
each economizer hopper is usually equipped with a
secondary storage hopper to continuously receive
this ash from the hot gas stream and reduce its tendency
to sinter. The ash can then be transported conventionally,
with each hopper equipped with an airlock valve or
materials handling valve to feed the material into the
transport piping. A less costly alternative is to feed
several economizer hoppers into a single secondary
hopper through the use of downcomers. However,
the physical layout of equipment in the economizer area
often precludes this arrangement.
Mechanical drag technology can also be used for
economizer ash. In this application, the drag unit is dry
and sealed. A single drag unit will normally collect from
all the hoppers on the economizer. The ash will then
be discharged through the rotary feeder into a single
storage tank which will feed an airlock valve, or materials
handling valve.

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Allen-Sherman-Hoff has been a pioneer in ash handling manufacturing engineered capital equipment for the
systems since 1917. Over the decades, the company power, iron and steel, chemical processing, pollution
has designed and supplied thousands of systems for control and other industries. The resources of the
utilities and a variety of industrial installations both corporation have further strengthened Allen-Sherman-
in the United States and abroad. Hoff's position as a leading supplier of ash handling.
The A-S-H Engineering Department has contributed equipment for all types of coal, oil and refuse fired boilers.
numerous advances which have been adopted as A-S-H has a complete line of equipment for industrial
industry standards. Today, the Engineering Department plants and also sells systems worldwide through
is deeply involved in producing systems and equipment Ecolaire's extensive sales office network.
to meet the increasing challenges of environmental
protection and gr~ater energy efficiency. High speed
computers and automated drafting equipment are
used to increase the accuracy, and decrease preparation
time of contract documents and drawings.
Allen-Sherman-Hoff's research and development
activities are geared to developing new technologies
and equipment for tomorrow's fossil fueled boilers.
Allen-Sherman-Hoff's Field Service Department offers
complete project management services for the erection,
check-out and start-up of ash handling systems. These
optional erection management services can be supplied
on either of two levels of activity; an A-S-H construction
supervisor advising the customer and his construction
organization, or a complete turnkey installation by
Allen-Sherman-Hoff.
Regional Customer Servicemen regularly visit the
plants in their assigned areas to discuss ongoing system
and equipment operation with plant personnel and
provide suggestions for improvements in equipment
and maintenance procedures. A-S-H offers specialized
training programs for operations and maintenance
personnel. These programs gre individually structured
to address the requirements of each specific installation
and are based on the detailed, custom generated manuals
that are provided for all customers.
Due to the severity of ash handling service, and the
resulting demands on equipment, Allen-Sherman-Hoff
dedicates major resources to its renewal parts and
service operations. A multi-million dollar inventory of
components, subassemblies, pipe and fittings is
maintained at a modern warehouse facility in Honey
Brook, PA. A computerized system expedites parts
shipment, monitors inventory, and alerts the replacement
parts department to any Allen-Sherman-Hoff engineering
changes since the original system installation. In
terms of customer benefits, the parts control system
provides for faster parts deliveries and the incorpora-
tion of system improvements.
Allen-Sherman-Hoff is an operating company within
Ecolaire Incorporated, a multi-divisional organization

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