Circumix® 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 components 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 

environmentally 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 residues. 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 bituminous 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 bed 

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 granulate. 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. Fly 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 (PCF) 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 the 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 desulfurization, 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. The 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 large contact surface. Fly 

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

MgO, SiO2, SO3(SO4), Al2O3 and Fe2O3 as well as complex 

compounds such as calcium-aluminate and glassy 

particles.

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

but another 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 diagram the fly 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 abundant 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 Circumix 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/cm3. 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 controlled 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 pumps.

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 water 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 slurry 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 or 

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 

below 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 

gravity.

The makeup water enters the cylindrical shaped premixer 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 arranged 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.

The 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 of the slurry mixture, 

considering the chemically reactive CaO(free) and 

CaSO4 components of the ash.

The long distance transport slurry pump for the byproduct 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 intensively 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 

supervision. 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 disposal 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 product itself is suitable for 

insulation, additional lining is not required.

 density

Density of ash stone is more than 1.3 kg/dm3

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/cm2

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 m3

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 ash 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 delivery 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 and 

mechanical agitation still

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

Ash stone recycling: foundations for a 10,000 m3oil tank

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

admixed.

1998: The first project (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
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 000Tatabányai Erőmű Kft. Hungary 2802 Tatabánya, Pbox. No. 201. 30 1993-2000 4.000 - 20 No 30 840 000AES 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. 836 1998- 8.000 4 x 20 4 x 160 Yes 480 23 040 000SC Collterm SA Romania 30092 Timisoara, Lonovici 4. 50 2000- 3.500 3 20 No 30 1 050 000Jacksonville 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 000Rovinari 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 properties

Silica as SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO3

Dense slurry properties:

Applied technology:

Scope:

Commissioned in:

Complete Dense Ash Slurry Handling System Delivery (main contracting)

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/m3

Intermittent (Emulgat) mixing technology

Engineering, Procurement, and Construction (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 SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO3

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 m3capacity 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/m3

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 SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO3

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, Hungary

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

2*100 m3/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/m3

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 SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO3

Alkalis as Na2O

Alkalis as K2O

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 m3/h slag slurry thickener

3*240 m3/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 - 49.0 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 / Water mixing ratio: 1:1

Slurry mass density: 1.35 t/m3

CIRCUMIX® continuous hydraulic mixing technology 

Engineering, Procurement, and Construction (EPC) turnkey project

1990/93
Timisoara Sud Power Plant (Romania) 

Project Name:

Project Owner:

Location:

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 SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO3

Dense slurry properties:

Applied technology:

Scope:

Commissioned in:

Complete Dense Ash Slurry Handling System Delivery (Equipment delivery and 

technology supply)

Timisoara Sud Power Plant Co. Ltd.

Timisoara, Romania

1*20 tons/h of dry solids mixing units (bottom ash/fly-ash)

1*30 m3/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/m3

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:

Location:

Equipment:

Design ash mass flow/mixer

Bed ash

Fly ash

Total ash

Fuel type:

Fuel ash properties

Silica as SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

Calcium oxide as CaO

Magnesium oxide as MgO

Sulphur as SO3

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 Station

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 m3/h, 1.7 km long transport lines

2 piston diaphragm type slurry transport pumps

slurry 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 flow rate: 120 m

3

/h/ 2 lines

Solids / Water mixing ratio: 1.5:1

Slurry mass density: 1.6 t/m3

CIRCUMIX® continuous mixing technology 

Engineering, Procurement, and Construction (EPC) turnkey project

2003
Craiova-II. Power Plant (Romania) 300 MW

Project Name:

Project Owner:

Location:

Capacity:

Specific electric self-consumption for 

CIRCUMIX

Fuel type:

Fuel ash properties

Silica as SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

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)

Craiova-II. Power Plant Co. Ltd.

Craiova, Romania

48.6 t/h ash flow

3*120 m3/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 m3/h

Solids / Water mixing ratio: 1:1

Slurry mass density: 1.34 t/m3

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

Bottom ash

Fly ash

FGD dense gypsum

Total ash

Fuel type:

Fuel ash properties

Silica as SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

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 m3/h of dense slurry (2 in operation / 2 reserve)

4.6 km long slurry transport 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 m3/h

Solids / Water mixing ratio: 1:1

Slurry mass density: 1.35 t/m3

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 SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

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 m3/h of dense slurry (2 in operation / 2 reserve)

5.6 km long 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 m3/h

Solids / Water mixing ratio: 1:1.1

Slurry mass density: 1.41 t/m3

CIRCUMIX® continuous hydraulic mixing technology 

2009
Turceni Power Plant (Romania) 2310 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 SiO2

Alumina as Al2O3

Iron oxide as Fe2O3

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 m3/h of dense slurry (2 in operation / 2 reserve)

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*235 m

3

/h

Solids / Water mixing ratio: 1:1

Slurry mass density: 1.41 t/m3

CIRCUMIX® continuous hydraulic mixing technology 

2012 (Under construction)
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Excellence • Passion • Integrity • Responsibility • GEA-versity

4-20 Irinyi J. Str, Science Park, Bldg."B", Budapest, H-1117, Hungary; Postal Address: P.O. Box 192, Budapest, H-1507, Hungary

Registered Office: Budapest; Court of Registration: Budapest Metropolitan Court, Cg. 01-10-041888

Executive Board: András Balogh (President & CEO), László Ludvig, Tamás Lelkes, János Hangyál

Chairman of the Supervisory Board: Christoph Michel 

GEA Heat Exchangers

GEA EGI Contracting / Engineering Co. Ltd.

Sales Business Unit ACC / Heller 

Balance of Plant

www.egi.hu

egiinfo@gea.com

Irinyi J. u. 4-20. Science Park Bldg “B”. 

H-1117 Budapest, Hungary

Géza Walter PhD BU Vice President for BOP 

Systems

Tel: +36 1 22-56-263

Fax: +36-1-22-56-264

email: geza.walter@gea.com

Péter Fazekas Head of Project Management

Tel: +36 1-22-56-340

Fax: +36-1-22-56-264

email: peter.fazekas@gea.com