Information

FlyAsh andDry Product Handlingfor Flue Gas Cleaning

I BAU HAMBURG

2

Systems and componentsfor power plantsIBAU HAMBURG not only suppliessystems and components for powerplants but also complete customisedsolutions for handling fly ash, pulveri-sed limestone, quicklime and gypsum.

Fly ash handling

• Conventional coal-firedpower plants

• Circulating fluidized bedpower plants (CFB)

Pulverised limestone,quicklime, hydrated limeand gypsum handling

• Wet flue gas cleaning(Wet FGD)

• Dry flue gas cleaning(Dry FGD)

We supply turnkey ash removal sys-tems from filter discharge to loadingof the fly ash, designed according tocustomer specifications and of courseassist with the planning.

Main IBAU components:

Pneumatic conveying installations:• Fluidslides• Pressure vessels• Screw pumps• Rotary air locks• Jet conveyors

Silo, storage and loadingtechnology:• IBAU large-storage silos• Steel silos with aerated bottom• Loading systems for pressure

vessel trucks• Pressure vessel truck discharge

Fly ash processing/homogenisation:• Mechanical mixers• Pneumatic homogenisation

technology• Classification technology ESP ash removal

Fly Ash Handling

IBAU Loading

IBAUFlow Control Gate

IBAUTwo-Way Valve

3

and ash storage silos

Information

IBAUScrew Pump

IBAUFluidslide

IBAU Rotary Air Lock

4

IBAU fluidslides at Power Plant Florina

Fly Ash Handling

Conveyingsystems

IBAU HAMBURG hasthe right conveying solu-tion in its programmewhatever the purpose:

Fluidslides:These systems are veryeconomical thanks to thelow energy consumptionand also 100% reliable inservice.

Ash removal can be per-formed for all hoppers of

one filter row via onlyone fluidslide. The fluid-slide slopes 5-7° fromthe horizontal. Given thehigh throughputs possi-ble the systems are alsosuitable for large quanti-ties of lignite fly ash.Screw pumps are used to

5

Information

IBAU pressure vessels at Power Plant Litvinov

transport the ash furtherup to conveying dis-tances of 500 m.

Pressure vesselconveyors:Pressure vessels functionaccording to the dense-phase flow principle.Several vessels are con-nected to one conveyingline. For different con-veying quantities diffe-

rent pressure vessel sizescan be combined. Theenergy consumption isrelatively low. Conveyingdistances > 1000 m arepossible. This means noother conveyors arerequired even with longdistances to the silo.

Jet conveyors:Jet conveyors are suitablefor fly ash quantities of upto 5 t/h and conveying dis-tances up to 100 m max.The specific material/ airratio is relatively low, andthe energy consumptioncorrespondingly high.

6

Fly Ash Handling

IBAU pumps during mounting

IBAU screw pump at Power Plant Mehrum

7

Information

IBAU jet conveyor for air preheater ash removal

8

IBAU central cone silo 25.000 m3 at Power Plant Mehrum

Fly Ash Handling

StorageIBAU HAMBURG sup-plies pneumatic systemsfor the storage of fly ash atpower plants. They functi-on according to the “first-in/first-out” principle.

IBAU central cone silos:These silos have provedtheir worth time and timeagain and are the industrialstandard for storage volu-mes up to 30,000 m3.

They are equipped with apneumatic discharge bot-tom and provide for mete-red and maintenance-freedischarge of material.

Multichamber design ispossible. The machineequipment and loadingsystems are situated under-neath the central cone.

Dome silos / Conversionof existing oil tanks:Pneumatic discharge solu-tions are possible in appli-cations where dome siloscan be used to advantage.

The bottom is also coveredwith fluidslides as with thecentral cone silo, and thematerial dischargedtowards the middle of thesilo. With this solution theloading point is installed atthe side of the silo. Old oiltanks can also be used forfly ash storage accordingto this principle.

Intermediate silos used tostore fly ash for furthertransport or loading aregenerally made of steel.They have either a flat orconical aerated bottom andare designed in sizes up to2000 m3.

9

Fly ash discharge from a central cone silo

Information

10

Fly Ash Handling

Intermediate silos in fly ash processing plant Maasvlakte

Discharge section of central cone silo after emptying residuesTypical discharge section of a central cone silo

11

Information

IBAU ash storage silos 15.000 m3 and 25.000 m3 at Power Plant Mehrum

12

Fly ashprocessingFrom being waste materi-al, fly ash has now beco-me a commodity. IBAUHAMBURG is supportingthis with innovative andeconomical technology.

Fly ash from an upstreamclassification system (e.g.using screen devices or airseparators) is processedinto high-quality ash witha continuous mechanicalmixer. Mixers with capa-cities ranging between100 to 250 t/h are usedhere. Classification forexample allows the carbonlevels to be kept belowpermissible limits orspecific finenesses to beseparated.

To satisfy the high qualityrequirements stipulated bythe cement and concretestandards additional flyash homogenisation maybe necessary with qualityfluctuations occurring dueto firing. At least two silosare required for such aconcept. One silo is usedto take up the fly ashduring operation whilehomogenisation is carriedout in the second silo.

The silos are equippedwith so-called “quadranthomogenisation” systems,which are used to fluidise,circulate and mix the con-tents of the silo section bysection.

IBAU fly ash homogenisation silos at Power Plant Mehrum

Fly Ash Handling

13

Information

IBAU flow-through mixer type IB-DM

View inside an IBAU flow-through mixer

I BAU Single-shaft flow-through mixerIB-DMThe mixer type IB-DMoperates according to theprinciple of centrifugalmixing. The mixing toolsare interchangeable andmounted on a rotatingshaft. The number andarrangement of the mixingtools and their geometricshapes are tuned to eachother, enabling a three-dimensional mixing move-ment of the components inthe cylindrical, horizontalmixer. All mixing tools aredesigned to ensure that thesupplied electrical energyis converted with the hig-hest possible efficiency.The dwell time of thematerial in the mixer canbe influenced via an over-flow weir. Throughput per-formances of up to 450 t/hcan be achieved.

14

Fly Ash Handling

Screen technology at IBAU fly ash processing installation Maasvlakte

Control room at IBAU fly ash processing installation Maasvlakte

15

Information

IBAU boiler ash processing at Power Plant Flensburg

16

IBAU lump crusher under absorber

Fly Ash Handling

IBAU HAMBURG sup-plies systems fromtruck/rail discharging ofabsorbents to the loadingof dry residual materialfrom flue gas desulphuri-sation (FGD).

Absorbents are deliveredby truck or rail pressure

vessel truck. Truckdischarge is carried outwith compressed air andpneumatic transport tothe storage silos. Hereconveying distances ofup to 100 m are possiblewith discharge capacitiesof up to 60 t/h per pres-sure vessel truck.

Storage silos have capa-cities of up to approx.2000 t and are equipped

with pneumatic dischargedevices. Lime, pulverisedlimestone and hydratedlime are used for dry orquasi-dry flue gascleaning. Material can betransported to the absor-ber with fluidslides. Theresidual material fromthe process is dischargedeither using fluidslides,rotary valves, screwpumps or pressure vesselconveyors.

Lime is transported fromthe storage silo, using ascrew pump for example,to the dosing silo forlime milk production.The wet flue gas gypsumis dehydrated and driedand after the dryerconveyed pneumaticallyto the gypsum storagesilo using screw pumps.

Flue gascleaning

17

Information

IBAU low-pressure conveying system for FGD product

18

Fly Ash Handling

Pressure vessel rail car discharge for pulverised limestone

Conveying air control unit for pressure vessel rail car discharge

19

Information

IBAU lime dosing upstream of absorber lime milk tank

20

IBAU pressure vessel for conveying bed ash

Fly Ash Handling

CombustionLow-grade coal and biofuels are being increasing-ly burnt in CFB pressurevessel installations andconverted into energy:here IBAU HAMBURGoffers appropriate conceptsand solutions for the han-dling of ash and lime.

Combustion bed ash witha grain size of up to2-3 mm is dischargedpneumatically fromthe combustion chamberor the ash cooler to thebed material silo or stor-age silo using a pressurevessel according to thedense-phase flow convey-ing principle.

Fluidslides, Fpipe andsmall pressure vesselshave proved to be effec-tive for the removal of flyash downstream of the fil-ter. The material is con-veyed to an intermediatesilo and is transported fur-ther to the ash silo using ascrew pump.

Pulverised limestone forexample is metered andblown in directly into thecirculating fluidized bedby a screw pump. Thefine-grained pulverisedlimestone ensures that fluegas desulphurisationalready takes place in thecombustion chamber.Besides sulphur most ofthe chlorine and fluorinebond to the dry ash.

21

Information

IBAU pulverised limestone dosing at VW Power Plant

22

Fly Ash Handling

ESP ash removal with IBAU fluidslides

23

Information

IBAU Fpipe conveying system for ESP ash removal

Fly Ash Handling

We supply customer-oriented solutions for loading and discharge, storageand the pneumatic conveying of dry product from

flue gas desulphurisation plants as well as for fly ash.

07/0

7

I BAU HAMBURG · Rödingsmarkt 35 · D-20459 Hamburg · PHONE +49 (0) 40 36 13 090FAX +49 (0) 40 36 39 83 · Email: info@ibauhamburg.de · Internet: www.ibauhamburg.de

FGD plant for Power PlantOroslany / Hungary

Combined dry ash and wet ash loading atPower Plant Mehrum / Germany

Fly ash processing plant Maasvlakte / Netherlands Power Plant Florina / Greece