bottom ash handling and fly ash handling
Bottom Ash Handling and Fly Ash Handling
In power plants and industrial boilers, ash is generated as a byproduct of the combustion process. Proper handling of bottom ash and fly ash is critical to ensure smooth operations, environmental compliance, and efficient resource management. Here’s a detailed overview of both systems:
Bottom Ash Handling
Bottom ash is the coarse, heavier ash that falls to the bottom of the boiler during combustion. It often contains slag, clinkers, and unburned material.
Common Systems for Bottom Ash Handling
- Submerged Flight Conveyors (SFC):
- Hot bottom ash falls into a water-filled trough.
- A flight chain system drags the ash to a dewatering section for disposal or further processing.
- Ideal for continuous ash removal.
- Dry Bottom Ash Handling Systems:
- Ash is cooled by ambient or forced air instead of water.
- These systems conserve water, reduce operational costs, and improve ash quality for reuse (e.g., in cement production).
- Hydraulic Systems:
- Ash is hydraulically transported from the furnace to a settling tank.
- Requires significant water usage, now less favored due to environmental regulations.
- Mechanical Conveyors:
- Drag chain, belt, or screw conveyors transport the ash without water.
Advantages of Modern Bottom Ash Handling Systems:
- Minimized water usage (or complete elimination in dry systems).
- Reduced operational and maintenance costs.
- Environmentally friendly with better ash quality for reuse.
Fly Ash Handling
Fly ash is the fine, powdery material that is carried with the flue gas. It is collected by pollution control devices such as electrostatic precipitators (ESPs) or bag filters.
Fly Ash Handling Systems
- Pneumatic Conveying Systems:
- Dense-Phase Pneumatic Conveying:
- Transports ash at low velocity to reduce wear and energy usage.
- Lean-Phase Pneumatic Conveying:
- Moves ash at higher speeds over shorter distances.
- Dense-Phase Pneumatic Conveying:
- Mechanical Systems:
- Uses screw conveyors, belt conveyors, or drag chain conveyors for short distances.
- Vacuum Systems:
- Utilizes negative pressure to collect fly ash from ESPs or bag filters and transport it to silos.
- Ash Storage and Disposal:
- Collected fly ash is stored in silos for recycling (e.g., in construction) or transported to disposal sites.
Advantages of Efficient Fly Ash Handling:
- Enclosed systems prevent dust emissions.
- Supports fly ash recycling and reduces disposal needs.
- Complies with stringent environmental regulations.
Key Differences Between Bottom Ash and Fly Ash Handling
| Aspect | Bottom Ash Handling | Fly Ash Handling |
|---|---|---|
| Nature of Ash | Coarse, granular, and heavier | Fine, powdery, and lightweight |
| Collection Point | Bottom of the boiler | Pollution control devices (ESPs, bag filters) |
| Handling System | Submerged or dry conveyors, mechanical | Pneumatic conveying, vacuum systems |
| Environmental Impact | Requires cooling (water or air) | Requires dust control systems |
| Reuse Potential | Aggregate for construction, landfill | Cement and concrete production |
Integration of Bottom and Fly Ash Handling Systems
A complete ash handling solution integrates both systems seamlessly to ensure continuous and efficient removal of ash. Advanced systems include features like:
- Centralized Control Systems:
- Real-time monitoring and control of both bottom and fly ash systems through SCADA or PLC systems.
- Ash Dewatering Units:
- Reduces water content in bottom ash for easier handling and transportation.
- Silo Storage Systems:
- Fly ash and bottom ash can be stored in separate silos with dust suppression systems.
- Ash Recycling Units:
- Bottom ash and fly ash are processed for reuse in construction, road base materials, or other industries.
Environmental Compliance
Both systems must comply with regulations such as:
- Limiting particulate emissions (e.g., from fly ash).
- Reducing water usage and wastewater discharge.
- Ensuring safe disposal of ash residues.
Modern dry ash handling systems have become the industry standard to achieve environmental sustainability.
Applications of Bottom and Fly Ash
- Bottom Ash Applications:
- Aggregates for construction.
- Raw material in cement and concrete production.
- Fly Ash Applications:
- Fly ash is widely used as a cement additive (a substitute for Portland cement).
- It is also used in road base stabilization, bricks, and tiles.
If you’d like assistance designing or improving a bottom ash or fly ash handling system, I can guide you with technical options and solutions tailored to your plant’s requirements! Let me know how I can assist.
Bottom and fly ash handling
- Bottom ash cooling screw
- Ash conveyors
- Bottom ash screen for sand recycling
- Ash container
- Fly ash cooling screw
- Pneumatic conveying systems
- Fly ash silo
- Dry and wet discharging systems
Features of the ash handling system
- Wide capacity range
- Wide cooling range
- High uptime with rugged, proven design
Basic Info.
Drag Chain Conveyor is a conveying device for continuously conveying powder, granules and small pieces of granular materials in a closed casing by means of a moving scraper chain. Since the scraper chain is buried in the material to be conveyed, it is called a buried scraper conveyor. When transporting horizontally, the material is subjected to the thrust of the scraper chain in the running direction. The material is conveyed forward with the scraper chain to form a continuous overall material flow.
Drag Chain Conveyor is widely used in metallurgy, building materials, power plants, grain, mining, food and other industry.
General Technical Parameter:
| Drag chain Conveyor Technical Specifications | |||||||
| Machine Item | MS25 | MS32 | MS40 | MS50 | MS63 | MS80 | |
| Chute Width(mm) | 250 | 315 | 400 | 500 | 630 | 800 | |
| Capacity(t/h) | 25/31.5 | 40/50 | 80/100 | 160/200 | 200/250 | 315/400 | |
| Max Conveying Distance(m) | 50 | 50 | 50 | 50 | 50 | 50 | |
| Scrapper Chain | Model | 3002T | 3002T | 3003T | 3003T | 3003T | 3003T |
| Allowable load(kn) | 33.4 | 45 | 100 | 100 | 275 | 2100 | |
| Weight(kg/m) | 13.87 | 15.36 | 25.34 | 25.34 | 47.6 | 52.32 | |
| Operating speed(m/s) | 0.16/0.20/0.25/0.32 | ||||||
- The traction chain has high strength and can be used for long distance transportation.
- Processes such as sorting, drying, cooling or assembly can be performed during the transport process.
- Drag Chain Conveyor is simple structure,light weight,small volume and floor space. Easy to produce, install and maintain.
- Flexible layout, horizontal or incline conveying materials can be realized. Continuous operation, multi-point feed and discharge.
- Conveying airtight, dustproof, anti-virus, explosion-proof. Ambient temperatures of -20 to +45 °C.
- Drag Chain Conveyor is widely used in conveying powdery and granular materials, and can realize multi-point feeding and multi-point unloading.
- The Drag Chain Conveyor is reasonable in design, simple in structure, and small in cross-section, which can reduce the installation space.
SELECTION & TECHNICAL QUESTIONS
Q1: How do I select the right conveyor model? What information should I provide?
> To recommend the most suitable solution, please provide the following details:
> 1. Material type: What material are you conveying? (e.g., fly ash, wood chips, biomass pellets, bottom ash, etc.)
> 2. Material properties: Particle size, temperature, moisture content, abrasiveness
> 3. Capacity requirement: How many tons per hour (t/h) do you need?
> 4. Installation conditions: Conveying distance, incline angle, space limitations
> 5. Application industry: Which industry is this for? (e.g., waste-to-energy plant, biomass power plant, cement plant)
> You can also email us or contact us via WhatsApp. Our engineers will get back to you within 24 hours.
Q2: What is the difference between screw conveyors and chain conveyors? Which one should I choose?
> Both types have different applications:
> – Screw Conveyors: Best for powdery and small-grain materials (e.g., fly ash, cement powder). Good sealing performance, simple structure, low maintenance cost.
> – Chain Scraper Conveyors: Best for bulky, highly abrasive materials (e.g., bottom ash, municipal solid waste, biomass fragments). Supports multiple inlet and outlet points.
> – Bucket Elevators: Ideal for vertical or steep-incline material lifting.
> If you are not sure, tell us your material and working conditions, and our engineers will help you choose.
Q3: Can your equipment handle high-temperature materials? What is the maximum temperature?
> We can customize equipment according to material temperature:
> – Standard type: 0~80°C, carbon steel
> – Medium temperature type: 80~200°C, thickened wear-resistant liner
> – High temperature type: 200~400°C, special heat-resistant steel, optional cooling jacket
> Please tell us your material temperature, and we will recommend the most suitable material solution.
Q4: Are there any limits on conveying distance and lifting height?
> Standard design range:
> – Screw conveyor: Single section up to 70 meters; multiple sections can be connected for longer distances
> – Chain conveyor: Single machine up to 60 meters
> – Bucket elevator: Lifting height up to 50 meters
> We can also customize for extra-long distances or special angles. Contact us for detailed solutions.
Q5: Do you provide explosion-proof design?
> Yes. For explosive and flammable conditions such as pulverized coal and biomass dust, we offer:
> – Explosion-proof motors (Ex d IIB T4 standard)
> – Reserved openings for explosion vents / rupture discs
> – Fully sealed structure to prevent dust leakage
> Please specify your explosion-proof rating requirements.
CUSTOMIZATION & MANUFACTURING
Q6: Do you support customization? What is the lead time?
> Over 90% of our equipment is customized according to customer working conditions. Standard models take about 90–120days. Special customizations take 120–180 days, depending on configuration complexity.
Q7: What material options do you offer?
> Common materials include:
> – Carbon steel (Q235B): Standard working conditions
> – Wear-resistant steel (NM400/NM500): Highly abrasive materials
> – Stainless steel 304/316L: Food, chemical, corrosion-resistant requirements
> – Bi-metal wear-resistant composite plate: Extreme abrasion conditions
> We will recommend the most cost-effective material solution based on your material properties.
Q8: What certifications do you have?
> We hold the following certifications:
> – ISO 9001:2015 Quality Management System
> – ISO 14001 Environmental Management System
> – ISO 45001 Occupational Health & Safety Management
> – CE Certification (EN 1090 Steel Structure)
> If you need scanned copies of specific certificates, please contact us.
DELIVERY & LOGISTICS
Q9: Which countries do you export to? Do you have export experience?
> Our equipment has been exported to more than 20 countries worldwide, including:
> – Europe: Germany, France, Poland, Turkey, etc.
> – Southeast Asia: Singapore, Thailand, Indonesia, Vietnam, etc.
> – Middle East: Saudi Arabia, UAE, etc.
> – South America**: Brazil, Chile, etc.
> We are familiar with the full export process: packaging, customs declaration, and ocean freight. We can provide FOB, CIF, and other trade terms.
Q10: What is your packaging method? Is it suitable for long-distance ocean shipping?
> Export-standard packaging:
> – Large items / complete machines**: Rust prevention + waterproof film + fumigated solid wood pallet
> – Precision components: Wooden case with shock-absorbing filling
> – Random accessories: Categorized packing with detailed packing list
> All wooden packaging meets IPPC fumigation standards for direct customs clearance.
Q11: What is your minimum order quantity?
> We do not have a strict minimum order quantity. Single-unit orders are welcome. Bulk orders can enjoy more favorable pricing.
INSTALLATION & AFTER-SALES
Q12: Do you provide installation guidance? Do engineers need to come to site?
> We offer two service options:
> 1. Remote guidance: Detailed installation drawings and operation manuals, video guidance for installation (free of charge)
> 2. On-site service: Dispatch engineers to site for installation and commissioning (travel costs are additional)
> Most customers choose remote guidance. Our equipment is designed as a modular structure for easy installation.
Q13: What is the warranty period? What are the wearing parts?
> Standard warranty period is 12 months (from the date of arrival at port).
> Wearing parts list:
> – Chain / screw flights: Approximately 1–3 years, depending on material abrasiveness
> – Liners: Approximately 2–4 years
> – Bearings: Approximately 2–3 years
> We recommend ordering a wearing-parts spare kit together with your first order.
Q14: How do you solve problems during operation?
> We provide 7×24 technical support:>
> – Response within 24 hours for technical issues
> – Remote video troubleshooting guidance
> – Engineer on-site service when necessary
> – Common spare parts in stock for fast delivery
QUOTATION & COOPERATION
**Q15: How can I get a quote? How long does it take?
> Quotation process:
> 1. You provide material parameters, capacity, installation conditions, and other requirements
> 2. Our engineers evaluate and select the appropriate model
> 3. Formal quotation and technical proposal provided within 7 working days
> You can contact us via email, or the online inquiry form.
Q16: What are your payment terms?
> Standard payment terms:
> – 30% advance payment: After contract signing, to start production
> – 70% balance: Before shipment, or against copy of Bill of Lading
For long-term cooperative customers, more flexible payment terms can be negotiated.
Follow these 3 steps to find your ideal conveyor solution
Step 1: Identify Your Material Type
Different materials require different conveyor designs. Tell us what you are conveying:
| Material Category | Examples | Recommended Conveyor Type |
| Powder / Fine Granules | Fly ash, cement powder, lime powder | Screw Conveyor |
| Small Granules / Pellets | Biomass pellets, plastic granules, grain | Screw Conveyor / Belt Conveyor |
| Fragments / Chips | Wood chips, bark, agricultural residues | Chain Scraper Conveyor |
| Bulky / Abrasive | Bottom ash, slag, MSW, clinker | Chain En-Masse Conveyor |
| Vertical Lift | Any bulk material needs vertical transport | Bucket Elevator |
Step 2: Define Your Working Conditions
Please prepare the following parameters before contacting us:
| Parameter | Why It Matters | Example |
| Capacity (t/h) | Determines conveyor size and power | 10 t/h, 50 t/h, 100 t/h |
| Conveying Distance (m) | Determines machine length | 15m horizontal, 30m incline |
| Incline Angle (°) | Affects capacity and design | 0° horizontal, 30° incline |
| Material Temperature (°C) | Determines material grade | Ambient, 150°C, 300°C |
| Moisture Content (%) | Affects discharge design | Dry, damp, wet (needs dewatering) |
| Abrasiveness | Determines liner thickness | Low, medium, high |
| Application Industry | Determines certification needs | Power plant, cement, mining, recycling |
Step 3: Choose Configuration Options
Based on your answers above, our engineers will recommend:
Material grade — carbon steel / wear-resistant steel / stainless steel
Sealing type — open trough / fully enclosed / gas-tight
Drive system — motor power, gearbox brand, speed range
Auxiliary options — explosion-proof motor, cooling jacket, cleaning device, level sensors
Not Sure Where to Start?
Send us your basic requirements, and our engineers will design a customized solution for you — completely free.
Email: bootec@bootecgroup.com Response time: Within 24 hours
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