Shanxi Taiyuan Power Plant Fly Ash Conveying Project

Project Background

A large coal-fired power plant in Taiyuan, Shanxi, faced challenges in handling fly ash generated from its daily operations. The plant required a reliable and efficient conveying system to transport fly ash from collection points to storage silos, while addressing environmental and operational concerns.

Client Challenges

The power plant experienced several issues with their existing fly ash handling approach:

• Frequent dust leakage during manual ash removal, leading to air pollution and health hazards for workers.
• High energy consumption due to inefficient pneumatic conveying routes and outdated equipment.
• Significant wear and tear on conveying pipes caused by the abrasive nature of fly ash, resulting in frequent maintenance shutdowns.
• Inconsistent ash flow rates that disrupted downstream ash utilization processes.

Solution Provided

To address these pain points, headpowder designed and implemented a sealed, automated fly ash conveying system tailored to the plant's layout and capacity requirements. Key elements of the solution include:

• A dense-phase pneumatic conveying system that minimizes air consumption while maintaining stable material flow.
• Wear-resistant ceramic-lined pipes and elbows to extend service life and reduce maintenance frequency.
• Advanced PLC control with real-time monitoring to ensure consistent feeding and remote operation.
• Integrated dust collection and venting mechanisms to achieve near-zero fugitive emissions.

Outcome and Benefits

After commissioning, the plant achieved stable 24/7 fly ash transfer with reduced energy usage per ton of material. Dust emissions dropped to negligible levels, improving workplace safety and compliance with local environmental standards. Maintenance intervals increased by more than threefold compared to the previous system, lowering overall operating costs.