AV Pump Dense Phase Pneumatic Conveying
AV Pump Dense Phase Pneumatic Conveying System for Fly Ash Handling in Power Plant
Efficient fly ash management is critical for power plant operations, balancing environmental compliance, operational safety, and cost efficiency. This case study explores how a thermal power plant in eastern China overcame challenges in low-volume fly ash transportation from boiler dust collectors to storage silos using our proprietary AV Pump Dense Phase Pneumatic Conveying System. By addressing precise throughput requirements, material sensitivity, and reliability demands, this solution sets a new standard for small-to-medium scale ash handling systems.
Project Background
● Low Throughput Requirement: Need for a stable 300-500 kg/h conveying capacity (6 pumps combined) to match intermittent hopper discharge cycles, avoiding over-engineering with large-scale systems.
● Material Characteristics: Fine fly ash (10-50μm particle size) with high bulk density (750 kg/m³), prone to bridging and pipeline blockages under inconsistent air pressure.
● Regulatory Requirements: Mandatory compliance with GB 13223-2011 emission standards, requiring dust-tight conveying to eliminate atmospheric pollution.
Solution: AV Pump Series Configuration
1. System Design
○ Model: 6 units of 42L AV Pumps in series connection under each hopper, optimized for coordinated low-volume conveying.
○ Key Parameters:
- Capacity: 300-500 kg/h total system throughput (6 pumps operating in synchronized cycles).
- Energy Consumption: 0.32 kWh per ton of fly ash, 25% lower than conventional dilute phase systems for similar volumes.
- Footprint: Compact vertical design (1.2m height per pump) enabling installation in standard hopper under-spaces without special structural modifications.
Technical Advantages Highlighted in This Case
1. Precision Flow Control for Low-Volume Applications
The AV Pump's modular series configuration allows adjustable conveying cycles to match hopper discharge rates (10-15 kg/min per hopper), ensuring stable 300-500 kg/h throughput without overloading pipelines. This eliminates the inefficiencies of "one-size-fits-all" large systems in small-to-medium scale scenarios.
2. Dense Phase Stability for Problematic Materials
By maintaining a solids-to-air ratio of 25:1, the system ensures gentle yet efficient transport of high-density fly ash, reducing particle degradation and pipeline wear. Over 10,000 operating hours, the system achieved a 99.8% blockage-free record.
3. Energy-Efficient Small-Scale Design
The patented air distribution system minimizes compressed air usage by 30% compared to generic dense phase pumps, achieving optimal energy balance for low-volume operations.
4. Plug-and-Play Integration with Existing Infrastructure
The pump's standard flange connection and 1.2m high profile requires no structural modifications to the dust collector hopper or flue height and can be installed seamlessly in a 1.8m high space.
5. Fully Sealed Emission Control
The hermetically sealed dome valve and pressure vessel design achieved a leakage rate <0.01m³/h, ensuring full compliance with China's strictest emission standards while eliminating dust-related safety hazards in the workplace.
This case demonstrates how the AV Pump Dense Phase Pneumatic Conveying System excels in applications requiring precise throughput control, the gentle handling of sensitive materials, and seamless integration with existing infrastructure. By prioritizing efficiency in small-to-medium scale operations, our solution redefines what's possible for power plant fly ash management—proving that performance and compliance can coexist without compromising on cost or complexity.
