June 2015

HASMUKH GOSWAMI COLLEGE OF

ENGINEERING
DESIGN ENGINEERING 1-B

Design for Separating Ash & Water By Hydraulic

Pressure

Design By :- Vedant Panchal-130240119075

Rutvik Patel -130240119115
Vishvkumar Patel-130240119127
Mehul Patel-130240119107

Supervisor
Prof. Kartik Trivedi & Gaurang Goswami
Mechanical Engineering Department,
HGCE,Ahmedabad.
June 2015

June 2015

Certificate
This Is To Certify That Mr.Panchal Vedant,Patel Rutvik,Patel Vishvkumar,Patel
Mehul, Enrollment No. 130240119075, 130240119115. 130240119127,
130240119107, Of Semester 4rd Branch Mechanical Engineering Has
Satisfactorily Completed The Project Work In Subject Design Of Engineering 1-B
With In Four Wall Of HASMUKH GOSWAMI COLLEGE OF
ENGINEERING, Vahelal, Ahmedabad

During Year 2014-15

Date Of Submission..

Sing. Of Staff In Charge

Sing. Of Head Of Department

( Kartik Trivedi )

(Amit Monpurwala)

June 2015

ACKNOWLEDGEMENT
Behind Every Achievement There Lies An Unfathomable Sea Of Gratitude To Those Who
Activated It, Without Whom It Would Never Ever Come Into Existence. To Them, Lay The
Words Of Gratitude Imprinted Within.
A Report Is All-Encompassing As This Is Never The Work Of One Or Two People Laboring In
Quiet Solitude. It Is The Product Of Many Hands, And Countless Hours From Many People. My
Thanks Go To All Those Who Helped Me In This Report.
I Would Like To Express My Sincere Gratitude To The Head Of The Mechanical Engineering
Department (HGCE) Prof. Amit Monpurwala And All Faculty Members Who Helped Me
Throughout My Studies.
And My Deepest And Sincere Thanks Go To My Guide Prof.Amruta Mali For His Extensive
Guidance, Encouragement, Immense Help And Cooperation Throughout.
Finally, thanks to all of our friends and families for continuous support and motivation
throughout the work.
Panchal Vedant (130240119075)
Patel Vishavkumar (130240119127)
Patel Rutvik (130240119115)
Patel Mehul (130240119107)

June 2015

ABSTRACT
An so and fly ash removal system for coal burning power plant stack gases which
provides for limestone dolomite addition to the coal carrying through the power
plant to form stable sulfate-sulfite compounds and unstable calcium and
magnesium oxides which will carry along with the fly ash particles to a scrubbing
zone.
The fly ash and the sulfate-sulfite compounds are counter currently contacted with
a descending alkaline scrubbing stream in the presence of self-cleaning mobile
contact elements in the scrubbing zone to elect the absorption of so and
Physical removal of fly ash and the stable sulfate and sulfite materials.
The continuously circulating alkaline stream used in the scrubbing zone is obtained
in part from the reaction of portions of the calcium and magnesium
Carbonates and oxides from the limestone-dolomite addition with re-circulating
water. It become slurry of ash
Slurry of the ash and alkaline going to the tank and it drop in the hydraulic system
the system push the all ash scrub and separating ash & water

June 2015

Chapter-1 INTRODUCTION

Introduction
What Is Coal Ash?
Coal Combustion Residuals, More Commonly Known As Coal Ash, Are
The Waste Byproduct Of Coal Fired Power Plants.
Coal Ash Residuals Include Fly Ash The Fine, Powdery Particles That
Float Up The Smoke Stack And Are
Captured By Pollution Control Devices And Bottom Ash The
Coarse, Heavier Materials That Fall To The Bottom Of The Furnace

Where Does All This Waste Go?

Coal ash may be stored uncovered ,unlined and unmonitored in surface
impoundment pounds or in landfills. The most common treatment of coal ash
slurry is the use of settling pound to separate solid waste form liquid. Solid
particles sink to the bottom of the pounds, while the liquid remain at the top to
be siphoned off when acceptably cleared and eventually released to surrounding
water
Coal ash is stored in nearly 1,000 disposal sites scattered throughout the
country.More than a third of all coal ash is ultimately disposed in dry Landfills,
frequently onsite at the power plant where the coal is burned.
Another fifth of coal ash is mixed with water and stored in ponds behind
Earthen dam walls. Because of lack of safeguards, some storage ponds are
That over forty percent of coal ash is recycled for beneficial use but that
figure is misleading and ignores the Threat of water contamination from
reckless reuse practices.
Much of the supposedly recycled coal ash is simply
Dumped into abandoned mines or quarries, and the national academy of
sciences has recommended that at Berkeley have estimated that approximately
25% of coal ash can be recycled safely and beneficially

June 2015

Definition
This Invention Relates To The Utilization Of Fly Ash For The Removal Of
Sulfur Dioxide From Flue Gases. Coal Fired Boilers For Power Plants And
The Like Must Comply With Emission Standards In The INDIA And In
Other Countries Throughout The World With Regard To Both Particulate Fly
Ash And With Sulfur Dioxide (S0) Emissions. In One Prior Art Approach
The Problems Are Treated Individually With The Fly Ash Being Collected
For Disposal And The S0 Being Removed By The Lime Or Lime-Stone
Slurry In A Scrubber Or Absorber. This slurry gave the water and the ash
particle by the hydraulic system.

June 2015

Chapter 2 : Canvas Sheet (NO Limits For Thinking)

The Meaning Of System
Hydraulic Pressure System Collect Ash As A Cake From & Separating Water .Its Water
Again Used In Water Scrubber System .

This Is The First Step Of The Project.In This Canvas,You Have To Find Out Who Are
The User Of Your Project?What Are Stakeholders?What Are The Activities?And What
Are Broad Stories About Activities?

2.2 User

In This Stage , We Find Out Various Users Which Are Directly Or Indirectly Related
To Our Project.

For Example

Industry Who Used Boiler

Used Of Boiler So Used Of Coil & Burning Of Coal Ash Are Made
Power Plant
In Power Plant Many Of Boiler Are Used To Produce Electricity And Tons Of
Coal Are Burned
Chemical Company
Chemical Used A HAG Machine For High Temp Air & Used Of HAG Machine It
Produced Ash
Foundry
Used Of Coal Furnace

2.3 Stakeholder
Stakeholder Means A Person Or An Organization With An Intrest.
For Example
Mechanical Engineer
State Pollution Control Board
Cement Company
Coalmine
Chemical Engineer

June 2015

Central Pollution Control Board

2.4 ACTIVITIES

Activities Mean All Those Things Which A User Can Do With The Help Of Our Project.

For Example
Save Environment
Used For Making Road & Cement

STORY BORDING

Happy

I M Work As Manager In Chemical Industry. Our Company Use Water Scrubber

System To Converted Fly & Toxic Gases To Liquid Scrub & Used Of Hydraulic
System We Separated Ash As A Solid Cake & Water
Our Company Use ESP System But Its Very Costly But This Design Is Cost And
Maintains Is Very Low

Sad

I M Work As Manager In Chemical Industry. We Use HAG Machine In Our Company

To Produced High Temperate For Hot Air. But Used Of HAG Machine Burning The
Coal Its Gave Cox,Sox & Many Harmful Gases
In Power Plant Use ESP System For Reduces Toxic Gas & Fly Ash But This Is
System Is Very Costly System Maintains Of ESP System Is Very High.

June 2015

Chapter 3 : Canvas Sheet (Ideation Canvas)

This Is The Second Step Of The Project. From The User Canvas, You Have An Idea That Who
All Are The Users Of Your Project What Are Their Activities And You Also Come To Know That
Your Project Is Used At Which Place Or Location And In What Kind Of Situation. In This
Canvas You Come Across Various Problems Faced By The User While Using Your Product. You
Also Come Out With Possible Solutions Of The Problems Faced By The Users In This Phase Of
Canvas

PEOPLE
Industry Who Used Boiler

June 2015

Power Plant
Chemical Company
Foundry

ACTIVITIES

Used Of Boiler So Used Of Coil & Burning Of Coal Ash Are Made

Power Plant Many Of Boiler Are Used To Produce Electricity And Tons Of Coal Are
Burned

Chemical Used A HAG Machine For High Temp Air & Used Of HAG Machine It
Produced Ash

Used Of Coal Furnace

Situation/Context/Location

Power Plant
Chemical Industry
Boiler Plant
Foundry

Props/Possible Solution
Ash Cake Used In Bricks
Ash Cake Used In Road Work
Ash Cake Used In Cement Company

Some Possible Solutions We Come Across Are As Follow :

Fly Ash In Blended Cement

The Cement Industry Is One Of The Largest Users Of Fly Ash . Fly Ash Finds Use In Blended Cements As
Hydraulic Binders In Which A Part Of Portland Cement Is Replaced By Fly Ash With Certain Pozzolanic
Characteristics. Major Advantages Of The Fly-Ash Blended Pozzolona Portland Cement Over Th Ordinary
Portland Cement,From The Consumers Point Of View, Include Reduction Inthermal Cracking And Good
Long-Term Strength.

Fly Ash In Bricks

According To National Surveys, Nearly 100 Billion Bricks (Which Use 300 MT Of Topsoil) Are Needed Every
Year In India. Estimates, Although Controversial, Suggest That Using Topsoil For Bricks Would Convert 3000
Hectares Of Fertile Land Into Barren Land Each Year (Suresh 1994). Fly Ash Is An Emerging Partial Replacement
For Clay In The Manufacture Of Bricks. It May Be Used Either With Clay As Part Replacement Or In Other
Combinations.

Fly Ash In Road Works

Fly Ash Is A Lightweight Substance And, Therefore, Embankments Using Fly Ash Can Be Constructed Over Soft
Ground. In Delhi, Fly Ash Was Used Successfully As A Filler In The Construction Of The Okhla Flyover, The
Hanuman Setu Approach Embankment, And In The Approach Embankments Of The Second Nizamuddin Bridge.
However, Such Success Stories Are Few And Far Between.

June 2015

Chapter 4 : Canvas Sheet (Product Development)

June 2015

Canvas 3 Is Known As The Product Development Canvas. In This Canvas You Come Across
Your Product Features , Product Function , The Purpose Of Your Product , User Experience
,Customer Revalidation And Product Redesign As Per Customer Revalidation.

Products Experience
So , Co & Other Harmful Gases Removed Easily
Lower Cost
Lower Maintenance

4.2 Products Function

Make Ash Cake
Moved Harmful Gases
Lower Waste Of Water

4.3 Products Fractures

Automatic Hydraulic Mechanism

June 2015

Slurry Inlet Automatically

Ash Cake Removing Automatically

4.4 Components

Hydraulic Press Machine

Hydraulic Pump
Filter Plate
Filter Paper
Hopper Tank
Feed Pump

4.5 Purpose
Save Energy
Save Environment
Save Money

4.6 Customer Revalidation

High Efficiency
Automatic Work

REJECT/REDESIGN/RETAIN
Users Liked Our Product But Some Suggestions Have Come Up By Our Users Like High
Efficiency And We Would Like To Inform Our Users That We Are Working On
Automation Work In Our Product So That Anyone Can Our Products

AEIOU FRAMEWORK

June 2015

AEIOU Is An Investigate Tool to Help Interpret Observations Gathered By

Ethnographic Practices In The Field.
Its An Observation Tool.
Its Primary Functions Are To Code Data And To Develop Building Blocks
Of Models That Will Ultimately Address The Objectives And Issues Of The
Client.
AEIOU Means :
1.
2.
3.
4.
5.

Activities
Environment
Interactions
Objects
Users

ACTIVITIES

June 2015

Activities Are Goals Directed Sets Of Actions-Path Towards Things People Want
To Accomplish . What Are The Models People Work In , And The Specific
Activities And Processes They Go Through.
General impressions / observations

Checking at main gate by security guard

Worker had doing there worked
Some people used there mobile
Operator operate the machine
Some worker take rest
Manager has visiting all plant
Some people drinking water

Elements ,features & special notes

Whistle
Mattel detector
Voky-toky
Mobiles
Water bottle

ENVIRONMENT

June 2015

Environmentincludes The Entire Arena Where The Activities Take Place.What Is

The Character Of The Function And What Is The Function Of The Space Overall ,
Of Each Individual Spaces And Of The Shared Spaces.
General impressions / observations (Style .materials , & atmosphere)

Hot
Noisy
Creepy smell
Chemical
Smoke

Elements ,features & special notes

Trees
River
Vehicles
Dust

INTERACTIONS

June 2015

Interactionsare Between The Persons And Someone Or Something Else ; They

Are The Building Blocks Of The Activities.What Is The Nature Of Routine And
Special Interactions Between The People ; Between People And Objects In Their
Environment , And Across Distances?

General impressions / observations

(who is interacting with whom, what?)

Manager told worker that close the water valve of machine.

Head manager asked assistant manager how their plant work.

Elements ,features & special notes

Mobile
Voky-toky

OBJECTS

June 2015

Objects Are Building Blocks Of The Environment , Key Elements Sometimes Put
To Complex Or Unintended Uses(Thus Changing Their Functions , Meaning And
Context).What Are The Objects And Devices People Have In Their Environments
And How Do They Relate To Their Activities

General impressions / observations

( what components are involved)

HAG
Water scrubber system
Hydraulic press machine
Hydraulic pump
Filter plate
Filter paper
Hopper tank
Feed pump

Elements ,features & special notes(how objects are relating to the activities)

HAG machine gave high temp. Air

June 2015

Water scrubber system add water in to smoke of HAG machine

By using of hydraulic machine it compressed slurry
Feed pump is used to send slurry toward mechanism
Filter paper is used to filter slurry

Inventory of key objects

Separated ash & water

Removed SO
Control of wastage of water

USERS

June 2015

Users Are People Whose Behaviours , Preferences And Needs Are Being
Observed.Who Is There?What Are There Roles And Relationships?What Are Their
Values And Prejudices?
General impressions / observations (who is present roles & responsibilities ?)

Power plant
Industry who used boiler
Chemical company
Foundry

Elements ,features & special notes (list of identified people involved)

Used of boiler so used of coal & burning of coal ash are made
In power plant many of boiler are used to produce electricity and tons of coal are
burned
Chemical company used a HAG machine for high temp air & used of HAG machine
it produced ash
Used of coal furnace

LEARNING NEEDS MATRIX(LNM)

June 2015

Learning Needs Matrix(LMN) helps us to identify the learning requirements at

an early stage along with prioritization of specific learning along with defined time
duration / time allocation for each learning priority.
Applicable standards and Design specification/Principles & Experiments:
Pascals law Px=Py=Pz

Components Materials & Strength Criteria :

Hydraulic pressure machine
Feed pump
Filter paper

Software tools/Stimulation Methods /Skills :

No Method used

Theories/Methods/Application Process Involved/Mathematical Requirement :

Px=Py=Pz
Hydroulic pressure machine for giving high pressure to compress slurry

June 2015

Appended Papers
This thesis consists of an introductory part and the following eight appended
papers:
paper a
find the meager problems to removing the fly ash in foundry and chemical
company
paper b
to make a ideal machine to remove the fly ash in low budget
paper c
type of coal used in company and its fly ash percentage also their properties
paper d
to make a machine in low space required and give high efficiency with
automatic work
paper e
design of which type of filter paper used in it
paper f
type of material used and their properties
paper g
about how to hydraulic machine working on this system
paper h
vibrations, temperature, flow of water & volume of slurry effect on the system