# C ircumix ® 

# Dense Slurry Technology

Competent solution for handling combustion residues for coal fired power plants

Power generation by the use of coal is necessarily a polluting technology?

What can be done to minimize environmental impact?

Is there any technology which reduces working costs and harmful environmental impact

simultaneously?

engineering for a better world GEA Heat Exchangers

## Introduction

Operation of thermal power stations is always

accompanied with some kind of environmental pollution.

Carbon dioxide and nitric oxides are, for instance, harmful

to the ozone layer, carbon monoxide is a hazardous gas,

sulphuric oxides cause acid rains and solid particles often

carry heavy metals that pollute the vegetation and the

natural water resources. Various technologies were

developed and introduced in order to minimize or to

eliminate these unfavourable effects. Carbon dioxide

emission can be reduced by increasing plant efficiency,

DENOX and DESOX technologies are applied in order to

remove harmful c omponents from the flue gases, more

efficient fly ash or dust precipitators are introduced and,

finally, more effective ash processing is adopted for

environmentally friendly disposal of firing residues.

The Circumix process provides solution for the

envi ronmentally compatible handling i.e. for collection,

processing and disposal of firing residues. Its

environmentally friendly features are favourable in

licensing and operation of coal firing power stations.



## Combustion Residues

Coal burnt in power plant boilers always carries some ash

which must be continuously removed.

A 500 MW power plant unit may consume, for instance,

three million tons of coal a year and can produce about one million tons of bottom ash and fly ash together called

combustion residue s. During its 25 year lifetime this plant

produces some 20 million tons of residues which are

usually landfilled.

Quantity and composition of residues are basically

determined by the coal and ash quality and by the firing

technology applied. High grade bi tuminous coals contain

only a few per cent of ash in contrary to low grade brown

coals with up to 30 per cent inert content. In pulverized

coal firing boilers bottom ash and fly ash are produced in

contrary to the circulating fluidized bed boilers where be d

ash is removed from the furnace.

Bottom ash or bed ash may exceed 20 per cent of

residues.

Combustion residues are accumulated at various points of

the firing system. Bottom ash is removed by the water

filled ash scraper under the furnace as wet granu late. Dry

bed ash is removed from the furnace of the circulating

fluidized bed boiler and is cooled before further

processing. Fly ash is collected at the economizer, at the

air preheater, in the precipitator or dust collector and,

finally, at the stack. F ly ash particle size is, usually, less

than 200 micron and the temperature of the dry substance

may reach 150°C.

About 80 per cent of firing residues is collected as fly ash,

mostly in the precipitator.

Simplified picture of a Pulverized Coal Fired (P CF) Boiler with flue gas desulfurization. The combustion residues and

other wastes are collected and removed from different points

## Residues from Desulfurization

Various techniques are used for removing sulphuric oxides

from flue gases. One solution is t he recirculating fluidized

bed firing where pulverized limestone is introduced

already in the furnace in order to capture sulphuric oxides.

Excess limestone and calcium sulphite are removed with

the bed ash.

The most widely applied technology is, however, the wet

scrubbing where hazardous gaseous pollutants are

removed by injected limestone and water slurry. The

product is gypsum with 10 to 15 per cent water content.

Although this is marketable, in many cases it is simply

landfilled. Another by

- product is the heavily polluted

waste water that is blown down from the scrubber.

The quantity of calcium sulphite , gypsum and waste water

primarily depends on the sulphur content of coal which is

1 to 3 per cent in most cases. The amount of by products

from desulfu rization, though substantial, usually does not

exceed 20 per cent of fly ash. 

## Features and Composition of Residues

Bottom ash is recovered from the furnace as a mostly

amorphous and glassy material that is crushed to particles

less than 10 mm in size. Th e particles do not contain

soluble compounds and are, usually, transported as lean

ash

– water slurry.

Fly ash consists of particles of spherical shape with less

than 200 micron diameter. Due to its porous structure,

this material has low density and larg e contact surface. Fly

ash is mainly composed of various oxides, such as CaO,

MgO, SiO

2 

### , SO

3 

### (SO

4 

### ), Al

2 

### O

3 

### and Fe

2 

### O

3 

### as well as complex

compounds such as calcium

- aluminate and glassy

particles.

CaO and MgO are partly bound as sulphates , for instance,

but an other part is free. The latter plays important role in

processing. The free CaO and MgO dissolved in water

together with silicates and other components can develop

complex composites such as ettringite or silicate

- hydrates

and alumina

- silica

- hydrates.

Fly ash from brown coals is similar in composition to

cement and is frequently utilized as its substitute. When

processed, dry fly ash is mixed with water in order to

enable transportation and to get a solid product.

According to the ternary diagra m the fl y ash from brown coal is similar to cement.

Hard coal ash is less reactive since its lime content is very low

## Water to Solid Ratio

Just as in preparing and pouring concrete, water to solid

ratio (W/S) plays an important role in fly ash processing,

too. Three basic solutions are applied:

 moistened or semi

- dry ash system:

In this case (W/S) is about 0.3 and water is fully

used for slaking free CaO and activating other

components. The wet product is transported by

belt conveyor or by truck. Wet bottom ash and

wet gypsum can be added. At the landfill,

compacting and additional moistening are

advisable in order to ensure high density, high

strength and low permeability.

 dense slurry system:

(W/S) is in the range of 0.6 to 1.3. The thick fluid

which is the product of intensive mixing is

transported by pipelines and pumps. The

suspension disposed at the landfill becomes solid

ash stone within a few days.  thin (or lean) slurry system:

( W/S) is much higher here it is in the range of 5 to

20. Due to the abund ant water content solid

particles can be pumped to great distances but

since the important hydroxides are leached out,

the disposed material remains loose and ash

stone is hardly produced. Excess water is

recovered and reused in this system

.

GEA EGI’s Ci rcumix process operates with dense slurry.

## Mixing Process

In order to slake free calcium oxide and to activate other

compounds, fly ash and water demand intensive mixing.

In a few minutes homogenous suspension is produced

with its density in the range of 1.25 to 1.70 g/cm 3 

### . The

thick fluid is of grey colour and its temperature is usually

around 40°C.

Bottom ash granulate, gypsum and other solids can be

added later keeping in mind that water brought in by

these additives should not deteriorate the contr olled fluid

characteristics.

The mixers are designed for intermittent or continuous

operation. GEA EGI's patented Circumix ® 

### mixer based

system applies the latter solution.

The intensive agitation in the Circumix ® 

### mixer is achieved

by circulation slurry p umps. 

## Transportation of Dense Slurry

Dense slurry is a thick suspension of fly ash and water

which has higher density and viscosity than lean slurry.

This means that much higher pump heads are required for

transportation in pipelines than with clean wate r or lean

slurry.

The larger bottom ash or bed ash particles may be

suspended in the thick fly ash slurry.

In order to prevent settling of solid particles and blocking

of pipelines, flow velocity shall not decrease below a limit

value. When the dense slu rry plant is shut down its vessels

and pipelines must be drained and flushed with clean

water.

Variable speed centrifugal pumps or piston diaphragm

pumps are used for transportation. For power plant to

landfill distances over 4 km piston diaphragm pumps o r

hydro

- hoist can be used.

Connection diagram of the Circumix® mixing loop and distance transport line. (optional)

## Dense Slurry Mixer System and Related

Equipment

The Circumix ® 

### type continuous flow

- through mixer

has two mixing stages, the pre

- mixer head, and

b elow that the mixer tank for final mixing. The

equipment is specially designed for high and low

capacity ash handling applications in power plants.

A dosing device, such as a rotary dosing vane feeds

the dry ash from a storage silo into the pre

- mixer by

gr avity.

The makeup water enters the cylindrical shaped pre

mixer tangentially. The makeup water is dosed

proportionally to the ash flow.

One slurry pump circulates the homogenous dense

slurry from below the mixer tank to the pre

- mixer

slurry nozzles arran ged around the dry ash drop

tube.

The free slurry jet streams of the nozzles entrain the

ash, air and makeup water, like a multi

- jet injector.

The pre

- mixed slurry enters the mixer tank on top of

the mixer tank for final mixing and homogenizing. Other slurry pump(s) serve for transporting the

dense ash slurry from below the mixing tank,

through slurry circulation pipeline loop(s), back to

the upper level of the mixing tank, where the slurry

stream(s) is (are) entered tangentially into the mixer

tank.

T he final homogeneous ash slurry leaves the mixer

from the tank circulation loop(s) through a slurry

discharge valve. The slurry level is generally

controlled by the material feed.

The size of the mixer is designed so as to ensure a

proper residence time o f the slurry mixture,

considering the chemically reactive CaO(free) and

CaSO

4 

### components of the ash.

The long distance transport slurry pump for the by

product storage area can be either of centrifugal

type slurry pump(s) if the transport distance is not

too long or of positive displacement piston

diaphragm slurry pump type if the transport distance

is quite long requiring high discharge pressure.

The Circumix ® 

### vessel is the key component of the dense slurry process. Combustion residues and water are inte nsively mixed

here to produce homogenous suspension

## Control System

The dense slurry system is an integral part of the power

station technology. When all information is collected in a

central control room for processing, the required data are

transmitted via a data bus system. If the distributed

control philosophy is adopted, the dense slurry plant is

equipped with its own control room where operator

consoles and data loggers are placed. 

## Transportation of Dense Slurry

There are up to 100 pumps, valves, motors, etc. in a typical

plant supervised by a programmable computer. Fluid

density, flow and level are the main controlled

parameters.

The dense slurry plant is an auxiliary facility in the power

station that is capable to operate without continuous

sup ervision. The larger bottom ash or bed ash particles

may be suspended in the thick fly ash slurry.

Typical image, displayed on the monitor of the computer that supervises and controls the operation of the Circumix

process.

## Licensing

Licensing of dis posal is subject to local and international

regulations and requirements. Typical parameters that are

checked are the following:

 water permeability

This value is less than l0

- 8 m/s in ash stone. This

means that the produc t itself is suitable for

insula tio n, additional lining is not required.

 density

Density of ash stone is more than 1.3 kg/dm 3



### which is higher than the product from other

processes, consequently the landfill has less

volume.

 compression strength

The strength of ash stone is about 100

- 500 N /cm 2



### that is less than the strength of concrete but

more than sufficient in a landfill.

 quality of leachate

Ion content of leachate penetrating ash stone

may be less than the same in drinking water

which means potentially hazardous ions are

firmly bound in ash stone. Tests are carried out on samples of different sizes. Smaller

samples are prepared in laboratories and the

measurements are completed in a few weeks. More

reliable data are gained from larger samples up to 50 m 3



### volumes which require longer time to prepare and to test.

Similarly to concrete, the various parameters of ash stone

slowly change in time and the final values are reached

only after a year or two.

Ash stone produced by GEA EGI's Circumix ® 

### system have

always met the requirements and the authorities

approved the operation of the dense slurry system.



## Advantages of the Dense Slurry Disposal

System

 dry technology

 low water consumption

 low investment cost

 low operating and maintenance costs

 high landfill density and less volume

 solid a sh stone, no dusting

 slurry deliverable by pumps and pipelines

 pipelines can be laid underground

 low noise emission

 very little leachate

 low ash stone permeability

 waste water can be utilized to mix the slurry

 solid wastes are embedded

 low cost deliver y to great distance is possible

 slurry can be utilized for construction

 environmentally friendly power plant technology

1985: The first tests with slag

- fly ash

- water mixtures

1990: The first mixer in the Pécs Power plant, a batch process an d

mechanical agitation still

1992: The first continuous operation mixer in Tatabánya, Hungary.

Ash stone recycling: foundations for a 10,000 m 3 oil tank

1996: The first application for long distance discharge and with bed

- ash

admixed.

1998: The first pro ject (Mátra) with FGD slurry and plant waste water

utilization

2000: The first project in Romania

2003: Jacksonville (USA) project for petrol coke boilers, with two

- stage DSS

2008

- Large scale projects in Romania ( total capacity served: >6000MW)



### Circumix ® 

### has been continuously developed since 1985 Circumix ® 

### has been continuously developed since 1985

## References

Reference Plant Country Address of the Client Plants capacity (MW) Year of Hand - over Working hours / year Bottom Ash handled in TPH Fly Ash handled in TPH FGD Products handled (Yes / No) Nominal Dense Slurry flow rate

(m 3 /h) Total Dense Slurry disposed on landfill area (m 3 )

Pannon Hőerőmű Zrt. Hungary 7612 Pécs, Pbox

No. 19. 200 1991 - 2000 6.000 2 x 19,4 2 x 77,6 No 120 6 480 000

Tatabányai Erőmű Kft. Hungary 2802 Tatabánya, Pbox. No. 201. 30 1993 - 2000 4.000 - 20 No 30 840 000

AES Borsodi Energetikai

Kft. Hungary 3700 Kazincbarcika, Ipari út 7. 200 1996 - 2000 6.000 2 x 12 2 x 78 No 200 2 400 000

Mátrai Erőmű

Zrt. Hungary 3271 Visonta, Erőmű u. 11. 83 6 1998 - 8.000 4 x 20 4 x 160 Yes 480 23 040 000

SC Collterm

SA Romania 30092 Timisoara, Lonovici 4. 50 2000 - 3.500 3 20 No 30 1 050 000

Jacksonville North Side Generating Station USA 21 West Church

Street Jacksonville, Florida 32202 600 2003 - 8.000 2 x 62,5 2 x 62,5 Yes 120 6 720 000

SC Collterm

SA Romania 30092 Timisoara, Lonovici 4. 50 2002 - 3.500 3 17 No 30 840 000

Rovinari Power Plant Romania 020371 Bucuresti, Bulevardul Lacul

Tei 1 - 3. 1 720 2010 - 8.000 4 x 30 4 x 127 Yes 230 1 140 000

Craiova II. Power Plant Romania 020371 Bucuresti, Bulevardul Lacul

Tei 1 - 3. 300 2010 - 8.000 4 x 9,2 4 x 51 Yes 95 760 000

Isalnita Power

Plant Romania 020371 Bucuresti, Bulevardul Lacul

Tei 1 - 3. 630 2010 - 8.000 4 x 7 4 x 55,2 Yes 100 466 600

Total: 4 616 Total: 43 736 600

## Pécs Power Plant (Hungary) 200 MW

Project Name:

Project Owner:

Location:

Capacity:

Fuel type:

Fuel ash prop erties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO

3

Dense slurry properties:

Applied technology:

Scope:

Commissioned in: Complete Dense Ash Slurry Handling System Delivery (main contra cting)

Pécs Power Plant Co. Ltd.

Pécs, Hungary

3*100 tons/h of dry solids mixing units (slag/fly

- ash)

2 km slurry transport distance

Fly

- ash storage system extension

Brown coal

Bottom ash Coarse ash Fine ash

39.51 6.67 14.61 wt%

16.73 16.38 16.08 wt%

5.54 5.33 16.78 wt%

20.49 14.15 16.27 wt%

3.69 3.33 2.74 wt%

10.02 8.88 2.74 wt%

Transport flow rate: 120 m 3 /h

Solids / Water mixing ratio: 1:1

Slurry mass density: 1.3 t/m 3

Intermittent (Emulgat) mixing technology

Engineering, Procurement, and Co nstruction (EPC) turnkey project

1990/91

## Tatabánya Power Plant (Hungary) 30 MW

Project Name:

Project Description:

Project Owner:

Location:

Capacity:

Fuel type:

Fuel ash properties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO

3 Titan oxide TiO2

Others

Dense slurry properties:

Applied technology:

Scope:

Commissioned in: Complete Dense Ash Slurry Handling System Delivery (main contracting)

Filling up of an abandoned open pit mine for 2*20 000 m 3 capacity heavy fuel oil storage

and loading/unloading station implementation

Tatabánya Power Plant Co. Ltd.

Tatabánya, Hungary

2*20 tons/h of dry solids mixing units (fly

- ash)

0.5 km slurry transport distance

Brown coal

Fine ash

21

- 36 wt%

21

- 27 wt%

9

- 15 wt%

13

- 14.5 wt%

2

- 4 wt%

12

- 17 wt%

0.7

- 1 wt%

1

- 8 wt%

Transport flow rate: 30 m 3 /h

Solids / Water mixing ratio: 1:1

Slurry mass density: 1.38 t/m 3

CIRCUMIX® continuous mixing technology

Part of an Engineering, Procurement, and Construction (EPC) turnkey project

1993

## Borsod Power Plant (Hungary) 200 MW

Project Name:

Project Owner:

Location:

Equipment:

Fuel type:

Fuel ash properties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO

3 Titan oxide TiO2

Others

Dense slurry properties:

Applied technology:

Scope:

Commissioned in: Complete Dense Ash Slurry Handling System Delivery (EPC contracting)

Borsod Power Plant Co. Ltd.

Kazincbarcika, Hun gary

2*90 tons/h of dry solids mixing units (slag/fly

- ash)

2*100 m 3 /h piston type slurry pump

3 sets of dense slurry transport lines

0.5 km slurry transport distance

Brown coal

Ash mixture

54.4 wt%

20.2 wt%

5.8 wt%

6.1 wt%

2.0 wt%

7.7 wt%

0.6 wt%

3 wt%

Transport flow rate: 100 m 3 /h

Solids / Water mixing ratio: 1:1

Slurry mass density: 1.38 t/m 3

CIRCUMIX® continuous mixing technology

Part of an Engineering, Procurement, and Construction (EPC) turnkey project

1993

## Mátra Power Plant (Hungary) 836 MW installed capacity

Project Name:

Project Owner:

Location:

Capacity:

Design ash mass flow/mixer

Bottom ash

Coarse fly ash

Fly ash

FGD dense gypsum

Total ash

Fuel type:

Fuel ash properties

Silica as SiO

2 Al umina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO

3 Alkalis as Na

2 O

Alkalis as K

2 O

Dense slurry properties:

Applied technology:

Scope:

Commissioned in 

### : Complete Dense Ash Slurry Handling System Delivery (EPC contracting)

Mátra Power Plant Co. Ltd.

Visonta, Hungary

4*160 tons/h of dry solids (bottom ash/fly

- ash/FGD gypsum) mixing units

(2 in operation / 2 in reserve)

2*750 m 3 /h slag slurry thickener

3*240 m 3 /h, 3.6 km long transport lines

3 sets of centrifugal type slurry pumps in series per transport line

slurry distribution system at the discharge area

landfill operational technology

30 t/h

2 t/h

94 t/h

34 t/h

160 t/h

Brown coal (lignite) from local open cast mines

Fly

- ash Bottom ash

45.0

- 4 9.0 90.0

- 92.0 wt%

17.5

- 18.5 1.0

- 2.0 wt%

7.8

- 8.8 2.0

- 2.9 wt%

7.5

- 7.9 0.2

- 0.8 wt%

4.5

- 5.2 0.1

- 0.2 wt%

5.5

- 6.5 0.1

- 0.2 wt%

0.2

- 0.3 wt%

0.5

- 0.7 0.1

- 0.2 wt%

Transport flow rate: 240 m 3 /h

Solids / Wat er mixing ratio: 1:1

Slurry mass density: 1.35 t/m 3

CIRCUMIX® continuous hydraulic mixing technology

Engineering, Procurement, and Construction (EPC) turnkey project

1990/93

## Timisoara Sud Power Plant (Romania)

Project Name:

Project Owner:

Locat ion:

Equipment:

Design ash mass flow/mixer

Bottom ash (t/h)

Coarse fly ash (t/h)

Fly ash (t/h)

Total ash (t/h)

Fuel type:

Design ash mass flow rates

Bottom ash

Coarse fly ash

Fly ash

Fuel ash properties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as F e

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO

3

Dense slurry properties:

Applied technology:

Scope:

Commissioned in 

### : Complete Dense Ash Slurry Handling System Delivery (Equipment delivery and

technology supply)

Timisoara Sud Power Pla nt Co. Ltd.

Timisoara, Romania

1*20 tons/h of dry solids mixing units (bottom as h /fly

- ash)

1*30 m 3 /h 7 km long transport line

1 piston diaphragm type slurry transport pump

slurry distribution system at the discharge area

landfill operational technology

4.7

2.0

13.3

20.0

Petroleum coke / Bituminous coal

4.7 t/h

2.0 t/h

13.3 t/h

Ash mixture

49.96 wt%

21.36 wt%

8.86 wt%

9.29 wt%

3.34 wt%

3.11 wt%

Transport flow rate: 30 m 3 /h

Solids / Water mixing ratio: 1: 1

Slurry mass density: 1.3 t/m 3

CIRCUMIX® continuous mixing technology

Engineering, Procurement, and Construction (EPC) turnkey project

2002

## Jacksonville North

- side Generating Station (USA) 2*300 MW CFB Units

Project Name:

Project Owner:

Loca tion:

Equipment:

Design ash mass flow/mixer

Bed ash

Fly ash

Total ash

Fuel type:

Fuel ash properties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO

3

Free CaO

Dense slurry properties:

Applied technology:

Scope:

Commissioned in: Dense Ash Slurry Mixing Plant Delivery for the Ash Handling System delivered by United

Conveyor Corporation for project owner (equipment delivery and technology supply)

Jacksonville North

- side Generating Stati on

Jacksonville (USA / Florida)

2*62.5 t/h fly ash mixer units as fly ash slurry mixer (first stage)

2*62.5 t/h bed ash mixer units as final ash mixer (second stage)

2*60 m 3 /h, 1.7 km long transport lines

2 piston diaphragm type slurry transport pumps

slur ry distribution system at the discharge area

landfill operational technology

62.5 t/h

62.5 t/h

125.0 t/h

Brown coal

Ash mixture

9.71 wt%

1.25 wt%

0.69 wt%

52.52 wt%

3.57 wt%

22.01 wt%

18.0 wt%

Transport fl ow rate: 120 m 3 /h/ 2 lines

Solids / Water mixing ratio: 1.5:1

Slurry mass density: 1.6 t/m 3

CIRCUMIX® continuous mixing technology

Engineering, Procurement, and Construction (EPC) turnkey project

2003

### Craiova

- II. Power Plant (Romania) 300 MW

Pr oject Name:

Project Owner:

Location:

Capacity:

Specific electric self

- consumption for

CIRCUMIX

Fuel type:

Fuel ash properties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Dense slurry properties:

A pplied technology:

Commissioned in: Complete Dense Ash Slurry Handling System Delivery (equipment delivery and

technology system)

Craiova

- II. Power Plant Co. Ltd.

Craiova, Romania

48.6 t/h ash flow

3*120 m 3 /h of dense slurry (2 in operation / 1 reserve)

9.4 km long slurry transport line

1.68 kW/t ash

Brown coal

Fly

- ash Bottom ash

46.1 46.1 wt%

21.4 21.4 wt%

10.9 10.9 wt%

10.7 10.7 wt%

5.2 5.2 wt%

Transport flow rate: 3*120 m 3 /h

Solids / Water mixing ratio: 1:1

Slurry m ass density: 1.34 t/m 3

CIRCUMIX® continuous hydraulic mixing technology

2009

### Isalnita Power Plant (Romania) 630 MW

Project Name:

Project Owner:

Location:

Capacity:

Specific electric self

- consumption for

CIRCUMIX

Design ash mass flow/mixer

B ottom ash

Fly ash

FGD dense gypsum

Total ash

Fuel type:

Fuel ash properties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Dense slurry properties:

Applied technology:

Commissioned in 

### : Complete Dense Ash Slurry Handling System Delivery (equipment delivery and

technology system)

Isalnita Power Plant Co. Ltd.

Isalnita, Romania

2*315 MW installed capacity

76.7 t/h ash flow

4*120 m 3 /h of dense slurry (2 in operation / 2 reserve)

4.6 km long slurry transpor t line

1.23 kW/t ash

6.7 t/h

50 t/h

20 t/h

76.7 t/h

Brown coal

Fly

- ash Bottom ash

48.3 46.3 wt%

23.9 23.0 wt%

7.3 7.0 wt%

10.8 10.3 wt%

2.6 2.5 wt%

Transport flow rate: 4*120 m 3 /h

Solids / Water mixing rat io: 1:1

Slurry mass density: 1.35 t/m 3

CIRCUMIX® continuous hydraulic mixing technology

2009

### Rovinari Power Plant (Romania) 1320 MW

Project Name:

Project Owner:

Location:

Capacity:

Specific electric self

- consumption for

CIRCUMIX

Design ash mass flow/mixer

Bottom ash

Fly ash

FGD dense gypsum

Total ash

Fuel type:

Fuel ash properties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Dense slurry properties:

Applied technology:

Commissioned in 

### : Complete Dense Ash Slurry Handling System Delivery (equipment delivery and

technology system)

Rovinari Power Plant Co. Ltd.

Rovinari, Romania

4*330 MW installed capacity

190 t/h ash flow

4*270 m 3 /h of dense slurry (2 in operation / 2 reserve)

5.6 km lon g slurry transport line

1.17 kW/t ash

30 t/h

127 t/h

33 t/h

190 t/h

Brown coal

Fly

- ash Bottom ash

47.2 45.3 wt%

22.1 21.2 wt%

10.2 9.8 wt%

8.7 8.3 wt%

4.7 4.5 wt%

Transport flow rate: 4*270 m 3 /h

Solids / Water mixing ratio: 1:1.1

Slurry mass density: 1.41 t/m 3

CIRCUMIX® continuous hydraulic mixing technology

2009

### Turceni Power Plant (Romania) 2310 MW

Project Name:

Project Owner:

Location:

Capacity:

Specific electric self

- consumption for

CIR CUMIX

Design ash mass flow/mixer

Bottom ash

Fly ash

FGD dense gypsum

Total ash

Fuel type:

Fuel ash properties

Silica as SiO

2 Alumina as Al

2 O

3 Iron oxide as Fe

2 O

3 Calcium oxide as CaO

Magnesium oxide as MgO

Dense slurry properties:

Applied technology:

Commissioned in: Complete Dense Ash Slurry Handling System Delivery (equipment delivery and

technology system)

Turceni Power Plant Co. Ltd.

Turceni, Romania

7*330 MW installed capacity

160 t/h ash flow

4*235 m 3 /h of dense slurry (2 in operation / 2 rese rve)

4.9 km long slurry transport line

1.19 kW/t ash

30 t/h

110 t/h

20 t/h

160 t/h

Brown coal

Fly

- ash Bottom ash

46.2 44.4 wt%

21.1 20.5 wt%

9.9 9.0 wt%

9.3 9.0 wt%

4.7 4.5 wt%

Transport flow rate: 4*23 5 m 3 /h

Solids / Water mixing ratio: 1:1

Slurry mass density: 1.41 t/m 3

CIRCUMIX® continuous hydraulic mixing technology

2012 (Under construction)

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Balance of Plant

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Systems

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email: geza.walter@gea.com 

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