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US20100294457A1 - Extraction and air/water cooling system for large quantities of heavy ashes - Google Patents

Extraction and air/water cooling system for large quantities of heavy ashes Download PDF

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Publication number
US20100294457A1
US20100294457A1 US12/438,126 US43812609A US2010294457A1 US 20100294457 A1 US20100294457 A1 US 20100294457A1 US 43812609 A US43812609 A US 43812609A US 2010294457 A1 US2010294457 A1 US 2010294457A1
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Prior art keywords
cooling
air
environment
extraction
feeding
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Abandoned
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US12/438,126
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English (en)
Inventor
Mario Magaldi
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Magaldi Power SpA
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Magaldi Power SpA
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Assigned to MAGALDI POWER S.P.A. reassignment MAGALDI POWER S.P.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MAGALDI, MARIO
Publication of US20100294457A1 publication Critical patent/US20100294457A1/en
Abandoned legal-status Critical Current

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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J1/00Removing ash, clinker, or slag from combustion chambers
    • F23J1/02Apparatus for removing ash, clinker, or slag from ash-pits, e.g. by employing trucks or conveyors, by employing suction devices
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2700/00Ash removal, handling and treatment means; Ash and slag handling in pulverulent fuel furnaces; Ash removal means for incinerators
    • F23J2700/001Ash removal, handling and treatment means
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2900/00Special arrangements for conducting or purifying combustion fumes; Treatment of fumes or ashes
    • F23J2900/01002Cooling of ashes from the combustion chamber by indirect heat exchangers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2900/00Special arrangements for conducting or purifying combustion fumes; Treatment of fumes or ashes
    • F23J2900/01003Ash crushing means associated with ash removal means
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2900/00Special arrangements for conducting or purifying combustion fumes; Treatment of fumes or ashes
    • F23J2900/01005Mixing water to ash
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23JREMOVAL OR TREATMENT OF COMBUSTION PRODUCTS OR COMBUSTION RESIDUES; FLUES 
    • F23J2900/00Special arrangements for conducting or purifying combustion fumes; Treatment of fumes or ashes
    • F23J2900/01006Airlock sealing associated with ash removal means
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23LSUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
    • F23L2900/00Special arrangements for supplying or treating air or oxidant for combustion; Injecting inert gas, water or steam into the combustion chamber
    • F23L2900/15041Preheating combustion air by recuperating heat from ashes

Definitions

  • the present invention relates to a system and a method for extracting, cooling and recovering energy for large quantities of heavy ashes produced by solid fuel boilers.
  • the known cooling systems do not succeed in implementing, in an efficient and effective way, the dry cooling or mainly dry cooling of the heavy ashes and the disposal of the related cooling air, above all if such ashes are in large quantities, with high content of unburnt matters and therefore at high temperature.
  • the dry cooling or mainly dry cooling of the heavy ashes and the disposal of the related cooling air above all if such ashes are in large quantities, with high content of unburnt matters and therefore at high temperature.
  • recovery of the thermal energy and disposal are succeeded to be obtained, they are achieved with considerable plant complications and with consequent very high implementation and handling costs.
  • the technical problem underlying and solved by the present invention is to provide a system and method for the extraction and cooling of heavy ashes coming from a solid fuel combustion chamber which allow obviating to the drawbacks just mentioned with reference to the known art.
  • the main advantage consists in that the present invention allows to carry out an adequate, effective and efficient dry cooling or mainly dry cooling of the ashes without exceeding the above-mentioned limit of 1.0-1.5% for the cooling air introduced into the combustion chamber from the bottom.
  • Such advantage is particularly important in the above-mentioned case of coals with high content of heavy ashes. This is mainly obtained by separating the whole extraction and transport system into two environments with different atmospheric pressure, the first one connected to the combustion chamber and the second one to the economizers' area. Such separation, among other things, allows sending to the latter area some air exceeding the above-mentioned 1.5% and the possible steam contained therein.
  • said environment separation is implemented by means of a head of the same transported ash and therefore substantially without the need of additional devices for the system.
  • This allows obtaining the above-mentioned effective cooling also of large flows of ashes with high temperature by keeping, however, an extreme construction and operation simplicity of the system itself, to the advantage of the implementation, handling and maintenance costs.
  • the invention substantially allows to optimize the system described in EP 0 471 055 B1 by widening the potentiality of applications thereof to large flows of heavy ashes coming from coals or lignites with high ash content.
  • the present invention relates to an extraction and air/water cooling system for large flows of heavy ashes, produced by solid fuel boilers, able to reduce the final temperature of the extracted ash, without increasing the air quantity entering the boiler throat, usually fixed by the boiler designers at a value around 1.5% of the total combustion air.
  • the air quantity necessary for cooling process exceeds the maximum quantity which can be admitted into the boiler, the system allows exceeding air to be sent to the fume duct in the most proper point thanks to a separation of the cooling environments made by the ash itself.
  • the separation of the environments of the cooling system is automatically handled by the system upon ash and/or flow measurement performed at the exhast. If the cooling air is not sufficient to cool the ash, the cooling effectiveness can be increased by adding atomized water.
  • the added water amount usually is dosed based upon the ash flow and temperature so as to guarantee the full evaporation of the injected water to obtain if necessary, at the exhaust, dry ash, suitable to be ground and transported pneumatically.
  • the water has the great advantage, with respect to air, to allow an effective cooling of the ash itself with considerable lower weight quantities (in a ratio around 1:100 under the working conditions which are considered in this case) and it allows then a drastic reduction of the air quantity to be sent to the fume duct. This allows reducing the negative impact, until making it practically negligible, that an increase in the quantity of the fumes involves for the possible oversize of the apparatuses and the increase in the energy necessary for treating the fumes themselves until the ejection from the chimney.
  • the proposed system upon use, is mainly constituted by:
  • FIG. 1 shows a general layout exemplifying a preferred embodiment of the invention system, in an operation mode which provides a pressure separation between two cooling environments;
  • FIG. 2 shows a schematic longitudinal-sectional view of a separation area of the two cooling environments of the system of FIG. 1 ;
  • FIG. 3 shows a cross-sectional view taken according to the line A-A of FIG. 2 ;
  • FIG. 4 shows a general layout exemplifying the system of FIG. 1 , in a different operation mode which does not provide said separation into two cooling environments;
  • FIG. 5 shows a cross-sectional view of a continuous mixer with double shaft equipped with nozzles for the cooling water of the system of FIG. 1 , taken along the line B-B of this last figure;
  • FIG. 6 shows a general layout exemplifying the system of FIG. 1 , in an operation mode which provides to send the still hot ash to the mixer of FIG. 5 .
  • a system for extracting and cooling combustion residues of the type used for example in solid fossil fuel thermo-electric plants and according to a preferred embodiment of the invention is designated as a whole with 1.
  • the system 1 is particularly suitable to handle large flows of heavy ashes, produced, for example, by the combustion of coals or lignites with high content of ashes.
  • the system. 1 Immediately downstream of the combustion chamber 100 , or better a transition hopper 105 thereof, the system. 1 provides a first extraction and/or transport unit, in particular a dry extractor 9 mainly made of steel with high thermal resistance.
  • a dry extractor 9 mainly made of steel with high thermal resistance.
  • Such extractor 9 is of the kind known on itself and described for example in EP 0 252 967, herein incorporated by means of this reference.
  • the extractor 9 gathers the heavy ashes which precipitate downwards into the combustion chamber 100 through the transition hopper 105 mentioned above.
  • the extractor 9 at the side walls of its own casing, has a plurality of entrance holes for the outer cooling air, distributed in a substantially regular way along the development of the extractor 9 itself and each one designated with 10.
  • Such entrances 10 can be equipped with means for adjusting the quantity or can be made active or deactivated.
  • the extractor 9 has an additional entrance for the outer cooling air 19 , preferably adjusted too by an automatic valve or by equivalent adjusting means of the flow and arranged substantially at an ending portion of the extractor 9 itself.
  • Cooling air is sucked through the entrances 10 and 19 within the extractor 9 and in countercurrent with respect to tranported ashes by the effect of the depression existing in the combustion chamber 100 . More in detail, air enters because of the depression existing in the transition hopper 105 , on the bottom thereof there is a depression adjusted by the control system of the combustion chamber 100 (generally around 300-500 Pa under the atmospheric pressure).
  • the ashes Downstream of the extractor 9 the ashes are fed to a breaker or crusher 3 , which crushes the coarsest fractions thereof so as to increase the thermal exchange surface and thus to improve the effectiveness of such exchange and thus cooling process.
  • an additional entrance for the outer cooling air is provided, designated with 17 and in case equipped, with means for flow regulation, as those already described. Also in this case, the air coming from the entrance 17 is fed in countercurrent through the crusher 3 itself and along the first extractor 9 by the effect of the depression existing in the combustion chamber 100 .
  • Such cooling air results useful not only for cooling the ash but also for cooling the machines.
  • the ashes are conveyed by means of a hopper/reservoir 8 to a second steel-belt conveyor-cooler 6 .
  • the described system configuration allows the hopper 8 to operate like a storage reservoir, by allowing to accumulate ash so as to guarantee the disconnection of the two atmospheres from the extractor 9 and of the conveyor-cooler 6 .
  • the conveyor 6 operates exactly as second extractor, by operating continuously under a material head which guarantees the separation between the environment of the extractor associated to the pressure of the combustion chamber 100 and the one of the conveyor/cooler associated to the different pressure of the economizers' area.
  • Sensors with maximum and minimum level designated with 7, and a layer leveller 18 , the latter arranged at an initial portion of the entrance of the conveyor 6 , are associated to the hopper 8 .
  • the position indicated by the layer regulator 18 connected to the value of the velocity of the belt of the conveyor cooler 6 provides information about the ash volumetric flow, useful along with the temperature measurement in order to regulate cooling fluids.
  • the ash continues to be cooled both by means of air resucked from outside through additional entrances 11 arranged onto the side walls of the extractor 6 itself in a way analogous to what already illustrated for the first extractor 9 , both, when needed, by means of water finely dosed by means of additional dispensing nozzles 12 positioned inside the covering of the conveyor 6 .
  • the system 1 is equipped with an air/water cooling system, implemented among other things by the air entrances 10 , 11 , 17 and 19 and by the water delivery nozzles 12 .
  • the system 1 further provides means for feeding the cooling air, heated after the heat exchange with the combustion residues, in a fume duct 101 associated to the combustion chamber 100 .
  • such feeding means comprises a duct 4 , properly insulated and thermally traced to avoid condensates, apt to be selectively adjusted and however interdicted/enabled by means of an automatic valve 15 (or equivalent means) arranged along the development thereof.
  • the duct 4 connects, or better is apt to connect, the discharge area of the conveyor 6 and/or incase of the mixer 2 to said economizers' area, under negative pressure too.
  • the duct 4 flows upstream of an air/fume exchanger 102 (fume side) apt to pre-heat the combustion air and typically provided in the combustion systems associated to the invention.
  • air/fume exchanger 102 can be of the type commonly called Ljungstrom.
  • the ash cooling onto the conveyor 6 is made more effective thanks to the presence of specific mixing means, in particular substantially wedge-shaped members 14 fixed with respect to the conveyor belt 6 itself and which in the present example have a shape like a ploughshare.
  • Such ploughshare-like members 14 are distributed in a substantially regular way along the development of the conveyor 6 and arranged at the ash transport section.
  • the ploughshare-like members 14 plough the ashes by operating a continuous mixing during the transport onto the belt, by exposing in this way the maximum surface available for the thermal exchange with the cooling air and/or water.
  • an automatic deviating valve 16 (or equivalent means for selectively deviating the ash flow) is provided, which allows to feed selectively the cooled ash to discharge means 13 directed outside or to a continuous mixer 2 , in the present example in communication with the outside too and shown in greater detail in FIG. 5 .
  • the discharge conveyor 13 is equipped with a device for controlling the entering air, not illustrated, to eliminate the uncontrolled entrance of air from outside (or, in embodiment variants, to connect the system to other transport or storage closed environments).
  • the mixer with water 2 allows completing the cooling of the ash if necessary to reach temperature values compatible with the downstream processes or to humidify the ash to reduce the dust emission under certain transport and disposal conditions.
  • the mixer 2 is equipped with a discharge hood 21 , equipped with means able to allow the ash discharge from the system by preventing at the same time an uncontrolled re-entering of the outside air.
  • Such device can be constituted for example by a valve with double clapet or by rubber flushes which, by deforming under the ash weight, allow the discharge thereof into the minimum required passage section.
  • a pipeline for connecting the mixer 2 to the duct 4 is provided for the outlet of the air and steam in the latter.
  • the system 1 then comprises means for sensing the temperature and/or volumetric and/or ponderal quantity of the ashes, which in the present example are arranged at the ending portion or at the discharge portion of the conveyor 6 and/or on the main extractor 9 or more preferably at the ash exhaust at the conveyor 13 .
  • sensors of the above-mentioned type are provided also at the hopper/reservoir 8 .
  • load cells or equivalent means can be provided to control the ash level in the hopper/reservoir.
  • temperature sensor means arranged at the duct 4 can be provided.
  • the system 1 comprises a control system, in communication with said sensor means, apt to control the operation modes of the system 1 in relation to the ash flow and temperature.
  • the ash temperature and/or flow values provided by the sensor means are compared by the control system to pre-fixed and stored values, and based upon the result of such comparison the operation mode most suitable to the operation of the system 1 is determined.
  • the ash temperature increase usually is linked to the increase in the flow thereof in the here considered system 1 .
  • the system in the starting phase is configured in the mode illustrated in FIG. 4 , by adjusting all air entrance valves 10 , 11 , 17 and 19 and by closing the automatic valve 15 , so as to obtain that the whole air quantity corresponding to 1.5% of the combustion air be sucked through the bottom throat of the hopper 105 of the boiler 100 by crossing in countercurrent the ash both in the extractor 9 and in the conveyor 6 .
  • Such operative mode is followed until the ash temperature at the exhaust of the conveyor 6 reaches the predetermined value T minimum .
  • control means act onto the relative velocity of the belt of the extractor 9 and of the belt of the conveyor 6 , substantially making so that the conveyor 6 have an ash potential flow greater than the extractor 9 in order to avoid the formation of a material head within the hopper 8 .
  • the system acts onto the velocity of the conveyor 6 , in particular by reducing and adjusting it so as to determine an ash accumulation in the hopper 8 and then to create a continuous ash plug and furthermore it opens the valve 15 of the duct 4 so as to create two different atmospheres respectively in the extractor 9 and in the conveyor 6 , the first one connected to the pressure existing in the boiler and the second one connected to the pressure existing in the fume duct.
  • the air valve entrances 10 , 19 and 17 of the extractor 9 and of the hopper 8 are automatically adjusted so as to concentrate in the extractor only the whole 1.5% of cooling air which can be introduced into the boiler.
  • the valves 11 and in case subsequently the nozzles 12 of the conveyor 6 are regulated by adding at first air until a percentage calculated so as not to influence on the systems for treating the fume downstream and subsequently water if necessary to reach the wished cooling.
  • the cooling air acting on the main extractor 9 introduced by means of the entrances 10 , 17 and 19 crosses such extractor in countercurrent and enters the combustion chamber 100 in the limit of 1.5%.
  • the cooling air exceeding 1.5% is taken from outside through the entrances 11 of the conveyor 6 , it crosses the latter in equicurrent and it is sucked through the duct 4 , together with the steam produced by the possible water local cooling, by the depression existing in the economizers' area.
  • FIG. 1 Such operative modes are exemplified in FIG. 1 .
  • the emptying of the load hopper 8 is avoided by controlling the velocity of the conveyor 6 depending upon the detections of the sensors of maximum and minimum level 7 .
  • the level reaches the minimum one the slowing is provided until stopping the conveyor 6
  • the re-starting of the conveyor 6 is provided and upon reaching the maximum level the increase in the speed and then in the quantity of the belt of the conveyor 6 is provided.
  • control means can make use of additional information detected by specific sensor means, related in particular to the ash temperature in the hopper 8 and to the feeding speed of the conveyor 6 .
  • the latter combined with the (fixed) value of the extraction section defines exactly the ash volumetric flow. It is clarified that the extraction level, in order to avoid possible problems in the extraction section itself, will have to be greater by a suitable margin in the size of the ash pieces outgoing from the crusher 3 .
  • the system 1 can be handled also in case of very high ash flows/temperatures—even higher than the design values—for example depending upon the kind of fuel or upon cleaning operations of the combustion chamber 100 .
  • the system 1 provides an operative mode like the last described and the discharge of the still hot ash to the mixer 2 instead of to the conveyor 13 by means of the deviating valve 16 .
  • mixer 2 an additional water flow could be introduced so as to bring the ash to the provided final temperature (typically indicatively 80° C.) with a proper humidity content (preferably around 10%) to guarantee the dust absence in the subsequent motion operations.
  • a proper humidity content preferably around 10%
  • an upside-down-“Y”-like connection can be provided directly between the conveyor 6 , the mixer 2 and the duct 4 . Thanks to such configuration, the air and in case the steam arriving from the conveyor-cooler 6 goes towards the connecting duct with the fume line by joining the steam generated in mixer 2 . The condensate risk remains in this connecting duct (between the mixer 2 and the main duct 4 ), which could be properly heated whenever the design conditions had identified danger of condensate formation and related ash incrustations.
  • prefixed values of temperature and/or flow and of predetermined amount of combustion air can be selectively set by an operator managing the system 1 .
  • a series of operative modes like the ones considered so far can be set manually or automatically by means of a managing and control system which, based upon the ash temperature/flow value, determines cooling mode of the ash itself by acting on the formation of the separation area, on the air—flows entering the extractor 9 and the conveyor 6 , on the possible dosage/usage of atomized water and on the activation of the deviating valve.
  • the system 1 has a total operative versatility and therefore the capability of managing practically any ash quantity, and this without problems associated to the introduction of an excessive flow of cooling air from the bottom of the boiler 100 .
  • such versatility is obtained by allowing the introduction of even very high cooling air flows and by feeding the additional air flow (which is not right to introduce from the boiler bottom in the fume duct) and by means of the possibility of adding, needed, also cooling water.
  • the system 1 through its control means, can dose adequately the used water quantity so that it vaporizes completely during cooling process and that, upon outgoing from the conveyor 6 , substantially dry ashes are then obtained suitable to be ground and transported pneumatically. This can be obtained by keeping ash final temperature above 100° C.
  • the water quantity to be atomized and injected will be controlled by means of a thermal balance which causes on one side the heat to be removed from the ash (quantity product for the variation in the specific enthalpy requested between the temperature in the hopper 8 and the discharge final temperature) and on the other side the sum of the water vaporization heat and the enthalpy variation subjected by the cooling air to be equal.
  • the temperature sensors arranged at the duct 4 apart from allowing a more complete control of the system parameters, also allow to verify the formation of possible condensation points at the whole duct 4 due to the steam deriving from the cooling water. In fact, knowing both the temperature of the air itself and of the atomized water quantity allows easily to calculate the humidity related to the cooling air and to verify that:
  • an additional connecting duct (or equivalent means) can be provided between the transition hopper 105 and the conveyor 6 near the hopper 8 , by moving selectively the entrance of the outer air on such duct and providing regulation valves of the quantity both of the hot air coming from the transition hopper 105 and of the cold environment air. This allows raising the air temperature in the system to such levels so as to eliminate the risk of condensate formation.
  • the above-mentioned adjustment of the entering hot and cold air flows could be then take place based upon the detections of the above-mentioned temperature sensor positioned on the duct 4 .
  • the invention allows an effective recovery of the energy deriving from having sent the maximum quantity of outer air on the extractor 9 and from having reduced drastically the air quantity on the second extractor 6 (for the water addition) and therefore the energy necessary for the fume treatment.
  • the invention has also as object a method for extracting and recovering energy of heavy ashes as described so far with reference to the system 1 .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Gasification And Melting Of Waste (AREA)
US12/438,126 2006-08-22 2006-08-22 Extraction and air/water cooling system for large quantities of heavy ashes Abandoned US20100294457A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IT2006/000625 WO2008023393A1 (fr) 2006-08-22 2006-08-22 Système d'extraction et de refroidissement par air/eau pour de grandes quantités de cendres lourdes

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US (1) US20100294457A1 (fr)
EP (1) EP2057414A1 (fr)
JP (1) JP2010501821A (fr)
CN (1) CN101506580A (fr)
AU (1) AU2006347454A1 (fr)
BR (1) BRPI0621950A2 (fr)
CA (1) CA2661591A1 (fr)
EA (1) EA015721B1 (fr)
MX (1) MX2009001889A (fr)
WO (1) WO2008023393A1 (fr)

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US20120288804A1 (en) * 2011-05-13 2012-11-15 Clyde Bergemann Drycon Gmbh Method and device for operating a conveyor for a combustion product
CN108225477A (zh) * 2018-01-12 2018-06-29 邯郸市邯钢集团信达科技有限公司 一种测量煤气布袋除尘筒体灰位的方法
US11135547B1 (en) * 2012-11-09 2021-10-05 Arkansas State University—Jonesboro Air cooled condensing heat exchanger system with acid condensate neutralizer

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DE102008052085B4 (de) 2008-10-17 2020-06-18 Clyde Bergemann Dryc0N Gmbh Anlage mit einer Fördereinrichtung für Verbrennungskessel
IT1392240B1 (it) * 2008-12-12 2012-02-22 Magaldi Ind Srl Sistema di estrazione e raffreddamento per grandi portate di ceneri pesanti con incremento dell'efficienza.
CN101660760B (zh) * 2009-05-20 2013-04-03 北京国电富通科技发展有限责任公司 一种干式输渣设备
US20120226089A1 (en) * 2011-03-03 2012-09-06 Covanta Energy Corporation Dry ash collector
CN105783006A (zh) * 2014-12-26 2016-07-20 青岛松灵电力环保设备有限公司 一种煤粉锅炉灰渣冷却输送方法及系统
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EA200900334A1 (ru) 2009-06-30
EP2057414A1 (fr) 2009-05-13
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MX2009001889A (es) 2009-06-08

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