Ash problems
- 1. ASH HANDLING PLANT PROBLEMSJISHNU VEMP NO-6106188BHEL ISG
- 2. PREVIEWEXCESSIVE COAL PILE DUSTSPECS AND TESTS TO GET BETTER COALUNEXPECTED COSTS IN BURNING COALCUTTING COAL MAINTENANCEOLD PIPING SYSTEM
- 3. 1) EXCESSIVE COAL PILE DUSTProblem description: Dust from coal pile blowing out to nearby houses- coal pile is a strip which is 1000ft long and 80 ft deep- Capacity of pile is around 30K tons nowMy suggestions: Occasional water spraying (install permanent water sprinkler) Dead storage should have semi permanent surface protection Use of fugitive dust control polymers Provision for thermal expansion and contraction of coal pile
- 4. Construction of concrete enclosure for coal pile Use of chemical sprays/petroleum resin/water emulsion Chemical crusting as dust controller Proper compacting of pile to ensure competent base for crust 2:1 slope for sides, sharp edges and ridges for piles Tank truck with a pump that can develop enough pressure to spray all portions of stock pile Weathering of coal piles can be prevented by latex polymer
- 5. 2) SPECS AND TESTS TO GET BETTER COALProblem description: The quality of coal in the last delivery has been below par. The reliable methods for weighing various factors to compare coals are not properly implemented. My suggestions: Following test analysis should be performed asap before the next deliverya) ASTM NO D-409 (Coal grindability)b) ASTM NO D-441 (fritability)c) ASTM NO D-1857 (Ash fusibility)d) ASTM NO D-3173 (Moisture content)
- 6. e) ASTM NO D-3174 (Moisture content)f) ASTM NO D-3179 (Nitrogen content)g) ASTM NO D-3177 (Total sulfur)h) ASTM NO D-2015 (Gross calorific value)NB: Samples should be taken for test, when coal is in motion
- 8. Review of coal specs: Ash softening temperature, grindability and delivery methods emphasizedCheck if fuel saving equipment like economizer was initially added or not in stage I
- 9. 3) UNEXPECTED COSTS IN BURNING COALProblem description: Excessive money invested in setting up big coal stack pile resulting in a delusion of safety. The flexibility in ash handling arrangement (ASHA) is really lowMy suggestions: The only possible solution is complete rework of the philosophy
- 10. 4) CUTTING COAL HANDLING MAINTENANCEProblem description: Maintenance of conveyors, crushers, vibrating feeders, elevators are really expensive Abrasion and belt wear seems to be really high Conveyor roller bearings are to changed at a frequency of 1 in 8 days Corrosion issues are more frequent
- 11. My suggestions: A) Predictive maintenance Operators should be alerted with noisy bearings, small breaks in belting and vibration in drives Lubrication, filter cloth replacement and induced draft fan cleaning program should be more frequentB) Predictive maintenancei) Equipment adjustment
- 12. ii) Repairsiii) Overhaul iv) LubricationOther possible solutions are listed below
- 13. Use of impact idlers
- 14. Coal from coal chute should be fed at the speed of conveyor belt movement
- 15. In order to get rid of excessive belt sagging, idler spacing and belt tension should be appropriate. The associate calculation sheets are attached
- 16. Prevent coal build up in the belt; scrappers can help Avoid belt misalignmentEffective bearing assembly scaling
- 17. 5) OLD PIPING SYSTEMProblem description: Inadequate capacity in some sections, corrosion and internal deposits, poor line supports, leaking valves and jointsMy suggestions: A) Stop line joint leakageB) Replace leaking valves, traps; batch repair for small valvesC) Making up more hangers and supportsD) Assign 1 more survey engineers
- 18. QUERIES
- 19. THANK YOU