Field Evaluation Services

Allen-Sherman-Hoff’s team of engineers are available to perform an evaluation of your

existing bottom ash system to determine the benefits that may be realized by conversion
to a MAC™ System. For more information about the MAC™ System, please contact an
Allen-Sherman-Hoff representative at 1-888-ASH-PARTS.

www.a-s-h.com 1.888.ASH.PARTS

MAC™ is a trademark of Magaldi Power S.p.A.

Allen-Sherman-Hoff is a division of Diamond Power International, Inc.

MAC™ Systems are supplied in the United States by Allen-Sherman-Hoff under a license
from Magaldi Power S.p.A.

This information contain herein is solely for informational purposes and is not offered,
nor should be construed, as a warranty or contractual obligation. Diamond Power

Magaldi Ash Cooler

International, Inc. Reserves the right to make design or material changes without notice. ™

Dry Bottom Ash System

©2005 Diamond Power International, Inc. All rights reserved. ASH-9342-0805-00


The patented MAC (Magaldi
™ Mechanical Seal
Ash Cooler) Dry Bottom
Ash System, is a unique system
for dry extraction, cooling and
handling of bottom ash from
pulverized coal-fired boilers.
With over 70 systems installed
worldwide, the MAC™ Dry Bottom
Ash System is the world’s leading
dry bottom ash-handling system
for utility boilers.
1
E
G
P A
The success of the MAC™ system can be
attributed to the following benefits over
traditional wet bottom ash systems:
• Eliminates water usage in cooling and conveying
bottom ash
• Reduces carbon content in bottom ash
• Captures heat energy from ash and returns to boiler
• Provides for potential sale of dry, low carbon ash
• Reduces operational and maintenance costs
compared to conventional wet systems
• Fully automatic system from boiler throat to
storage silo
The MAC™ System has been installed in
both new boiler and retrofit projects on many
different boiler types and makes in a wide
range of operating conditions.
WORKING CONCEPT
The main component of the MAC™ System is the MAC™ extractor, which is designed to operate in harsh conditions
including exposure to high temperatures and shock loads caused by the fall of large clinkers. The MAC™ extractor is
connected to the boiler throat through a refractory-lined hopper or a transition chute, which provides a volume for
temporary ash storage. The hopper is available with bottom doors which can be closed to isolate the MAC™ extractor
and for ash storage. The hopper or transition chute is connected to the boiler throat by a high-temperature mechanical
seal that allows for boiler expansion.
Superbelt
Boiler
Spill Chain
Bottom Doors (Optional) Hopper or Transition Chute
Crusher
Downstream Equipment
MAC Extractor
Operation The Magaldi Superbelt Construction
A key element of the MAC™ extractor is the Magaldi Superbelt Pan
which receives and extracts bottom ash falling from the boiler.
The Superbelt is enclosed inside the sealed casing of the
MAC™ extractor. During the conveying of ash on the Superbelt,
ash is cooled by a small, controlled amount of ambient air
Mesh Belt
that flows by natural draft into the MAC™ System casing
through inlet valves. In addition, the air provides oxygen to
Carrying Idler
the unburned ash, allowing a more complete combustion
and return of heat to the boiler. Data from existing installations
indicate reverse air flow does not disturb the combustion
The Superbelt is constructed with a stainless steel mesh belt that
carries partially overlapping stainless steel pans - making the belt
process and does not influence NOx formation. conveyor almost completely sealed.
The patented method of connecting the pans to the mesh belt
From the MAC™ extractor, the cooled ash is discharged leaves all components free to expand in any direction, without
onto a crusher, which reduces the large ash clinkers to a size permanent deformation. As a result, the Superbelt withstands
2
suitable for conveying to a silo. the high temperatures encountered under the boiler throat.
E
The Superbelt is supported by carrying idlers that are mounted
G
Any ash fines that fall on the casing floor are swept off by
across the entire width of the belt to provide support for heavy
P A
the spill chain, a small scraper conveyor installed under mechanical impacts. All idler bearings are fitted outside the casing
the Superbelt. to protect them from heat and allow easy lubrication. The driving
force is transmitted by friction between the head pulley and the
belt, while a pneumatic take-up device on the tail pulley supplies
a constant tension. Wear of the belt is minimized because there
is normally no relative motion between the belt and the ash.

The patented MAC (Magaldi
™ Mechanical Seal
Ash Cooler) Dry Bottom
Ash System, is a unique system
for dry extraction, cooling and
handling of bottom ash from
pulverized coal-fired boilers.
With over 70 systems installed
worldwide, the MAC™ Dry Bottom
Ash System is the world’s leading
dry bottom ash-handling system
for utility boilers.
1
E
G
P A
The success of the MAC™ system can be
attributed to the following benefits over
traditional wet bottom ash systems:
• Eliminates water usage in cooling and conveying
bottom ash
• Reduces carbon content in bottom ash
• Captures heat energy from ash and returns to boiler
• Provides for potential sale of dry, low carbon ash
• Reduces operational and maintenance costs
compared to conventional wet systems
• Fully automatic system from boiler throat to
storage silo
The MAC™ System has been installed in
both new boiler and retrofit projects on many
different boiler types and makes in a wide
range of operating conditions.
WORKING CONCEPT
The main component of the MAC™ System is the MAC™ extractor, which is designed to operate in harsh conditions
including exposure to high temperatures and shock loads caused by the fall of large clinkers. The MAC™ extractor is
connected to the boiler throat through a refractory-lined hopper or a transition chute, which provides a volume for
temporary ash storage. The hopper is available with bottom doors which can be closed to isolate the MAC™ extractor
and for ash storage. The hopper or transition chute is connected to the boiler throat by a high-temperature mechanical
seal that allows for boiler expansion.
Superbelt
Boiler
Spill Chain
Bottom Doors (Optional) Hopper or Transition Chute
Crusher
Downstream Equipment
MAC Extractor
Operation The Magaldi Superbelt Construction
A key element of the MAC™ extractor is the Magaldi Superbelt Pan
which receives and extracts bottom ash falling from the boiler.
The Superbelt is enclosed inside the sealed casing of the
MAC™ extractor. During the conveying of ash on the Superbelt,
ash is cooled by a small, controlled amount of ambient air
Mesh Belt
that flows by natural draft into the MAC™ System casing
through inlet valves. In addition, the air provides oxygen to
Carrying Idler
the unburned ash, allowing a more complete combustion
and return of heat to the boiler. Data from existing installations
indicate reverse air flow does not disturb the combustion
The Superbelt is constructed with a stainless steel mesh belt that
carries partially overlapping stainless steel pans - making the belt
process and does not influence NOx formation. conveyor almost completely sealed.
The patented method of connecting the pans to the mesh belt
From the MAC™ extractor, the cooled ash is discharged leaves all components free to expand in any direction, without
onto a crusher, which reduces the large ash clinkers to a size permanent deformation. As a result, the Superbelt withstands
2
suitable for conveying to a silo. the high temperatures encountered under the boiler throat.
E
The Superbelt is supported by carrying idlers that are mounted
G
Any ash fines that fall on the casing floor are swept off by
across the entire width of the belt to provide support for heavy
P A
the spill chain, a small scraper conveyor installed under mechanical impacts. All idler bearings are fitted outside the casing
the Superbelt. to protect them from heat and allow easy lubrication. The driving
force is transmitted by friction between the head pulley and the
belt, while a pneumatic take-up device on the tail pulley supplies
a constant tension. Wear of the belt is minimized because there
is normally no relative motion between the belt and the ash.
 SYSTEM CONFIGURATIONS
Since the ash is delivered dry, there are several options available for the configuration
of the equipment downstream of the crusher. The most commonly applied
configurations are described below.

Mechanical Conveying to Silo Pneumatic Conveying to Fly Ash Silo

The Magaldi Postcooler provides dry If the dry bottom ash is pulverized by mills to a
Post Cooler
mechanical transport to a silo. The Postcooler Post Cooler very fine size, it can be mixed with the fly ash. Pulverizers
Hopper
is a steel belt conveyor inside a sealed This can lead to a simplification of the overall ash
casing, providing further cooling of ash handling system and potential for increased ash
Crusher Silo
during the conveying process. sales revenues. In this configuration, usually a
Magaldi Postcooler is used to transport the ash To Fly
Hopper Ash Silo
from the crusher to the
pulverizers, followed by
Crusher
pneumatic conveying to
MAC Extractor the fly ash silo. MAC Extractor Pneumatic Pressure System

Pneumatic Conveying to Silo

Operations with space constraints will find

the pneumatic system beneficial because the Pneumatic Vacuum System
downstream conveying system can be routed
Primary Crusher
through very restricted spaces. A second Silo

crushing stage further reduces the size of

3

4
the ash before transport.
E

E
G

G
Hopper
P A

P A
MAC Extractor
Bin
Secondary Crusher
 SYSTEM CONFIGURATIONS
Since the ash is delivered dry, there are several options available for the configuration
of the equipment downstream of the crusher. The most commonly applied
configurations are described below.

Mechanical Conveying to Silo Pneumatic Conveying to Fly Ash Silo

The Magaldi Postcooler provides dry If the dry bottom ash is pulverized by mills to a
Post Cooler
mechanical transport to a silo. The Postcooler Post Cooler very fine size, it can be mixed with the fly ash. Pulverizers
Hopper
is a steel belt conveyor inside a sealed This can lead to a simplification of the overall ash
casing, providing further cooling of ash handling system and potential for increased ash
Crusher Silo
during the conveying process. sales revenues. In this configuration, usually a
Magaldi Postcooler is used to transport the ash To Fly
Hopper Ash Silo
from the crusher to the
pulverizers, followed by
Crusher
pneumatic conveying to
MAC Extractor the fly ash silo. MAC Extractor Pneumatic Pressure System

Pneumatic Conveying to Silo

Operations with space constraints will find

the pneumatic system beneficial because the Pneumatic Vacuum System
downstream conveying system can be routed
Primary Crusher
through very restricted spaces. A second Silo

crushing stage further reduces the size of

3

4
the ash before transport.
E

E
G

G
Hopper
P A

P A
MAC Extractor
Bin
Secondary Crusher
 OPERATING CHARACTERISTICS

Facilitates lower operation & maintenance costs

• Extended lifecycle - The Superbelt life is extended due to unique low
friction design.

• Resists plugging - The MAC™ extractor design ensures that any ash clinker
that can pass through the boiler throat is transferred to the crusher
Enhanced dependability and safety
• Low maintenance requirements - regular maintenance activities can be carried
The dependability of the MAC System can result in
™
out with the system in operation
increased boiler availability by: • Fully automatic operation - eliminates need for costly manual operations such
as use of front end loader to transfer ash from bunker to truck
• Reducing forced boiler outages - the MAC™ is designed so maintenance
and repair can be performed online • Lower energy consumption - because no water has to be moved, only dry ash

• Reducing risk of sudden failures - able to withstand the impact of large

clinkers falling from boilers
Heat recovery from the ash to the boiler

• Reducing safety risks - all moving parts are inside the casing and no In coal-fuel fired boilers, a significant amount of energy is contained in
rodding of ash is required the bottom ash. In a wet bottom ash system, this energy is completely lost
because the ash is quenched. In the MAC™ System, the cooling air captures
Reduces water-related problems the heat from the ash and provides oxygen for post-combustion resulting in:

By eliminating the use of water for ash cooling and conveying, • A substantial burn-out of remaining carbon in bottom ash

a series of operational and environmental problems are eliminated
when using the MAC™ System.
• Eliminates ash dewatering bins, ponds or waste water treatment
• Eliminates pumps, heat exchangers and pH-control
• Minimizes corrosion due to cooling and conveying water
5
• Significant recovery of heat contained in the bottom ash. This heat recovery
reduces the heat and fuel losses from the boiler which can contribute increased
boiler efficiency
It is routinely demonstrated that the amount of cooling air used in the MAC™
System (typically less than one percent of total boiler combustion air) does not
have an adverse effect on the boiler operation

6
• Eliminates risk of ice formation from wet ash
E

E
• Reduces safety problems due to hot water splashing or vapor explosions Delivery of dry ash
E P A3 G

P A G
• Reduces environmental impact due to waste-water discharge The bottom ash is delivered dry, which offers the following benefits:

• Simplified configuration of the downstream processing equipment

P A G

• After pulverization, dry low carbon content bottom ash can be mixed with
fly ash, leading to potential for increased ash sales revenues and simplified
ash management
 OPERATING CHARACTERISTICS

Facilitates lower operation & maintenance costs

• Extended lifecycle - The Superbelt life is extended due to unique low
friction design.

• Resists plugging - The MAC™ extractor design ensures that any ash clinker
that can pass through the boiler throat is transferred to the crusher
Enhanced dependability and safety
• Low maintenance requirements - regular maintenance activities can be carried
The dependability of the MAC System can result in
™
out with the system in operation
increased boiler availability by: • Fully automatic operation - eliminates need for costly manual operations such
as use of front end loader to transfer ash from bunker to truck
• Reducing forced boiler outages - the MAC™ is designed so maintenance
and repair can be performed online • Lower energy consumption - because no water has to be moved, only dry ash

• Reducing risk of sudden failures - able to withstand the impact of large

clinkers falling from boilers
Heat recovery from the ash to the boiler

• Reducing safety risks - all moving parts are inside the casing and no In coal-fuel fired boilers, a significant amount of energy is contained in
rodding of ash is required the bottom ash. In a wet bottom ash system, this energy is completely lost
because the ash is quenched. In the MAC™ System, the cooling air captures
Reduces water-related problems the heat from the ash and provides oxygen for post-combustion resulting in:

By eliminating the use of water for ash cooling and conveying, • A substantial burn-out of remaining carbon in bottom ash

a series of operational and environmental problems are eliminated
when using the MAC™ System.
• Eliminates ash dewatering bins, ponds or waste water treatment
• Eliminates pumps, heat exchangers and pH-control
• Minimizes corrosion due to cooling and conveying water
5
• Significant recovery of heat contained in the bottom ash. This heat recovery
reduces the heat and fuel losses from the boiler which can contribute increased
boiler efficiency
It is routinely demonstrated that the amount of cooling air used in the MAC™
System (typically less than one percent of total boiler combustion air) does not
have an adverse effect on the boiler operation

6
• Eliminates risk of ice formation from wet ash
E

E
• Reduces safety problems due to hot water splashing or vapor explosions Delivery of dry ash
E P A3 G

P A G
• Reduces environmental impact due to waste-water discharge The bottom ash is delivered dry, which offers the following benefits:

• Simplified configuration of the downstream processing equipment

P A G

• After pulverization, dry low carbon content bottom ash can be mixed with
fly ash, leading to potential for increased ash sales revenues and simplified
ash management
Field Evaluation Services
Allen-Sherman-Hoff’s team of engineers are available to perform an evaluation of your
existing bottom ash system to determine the benefits that may be realized by conversion
to a MAC™ System. For more information about the MAC™ System, please contact an
Allen-Sherman-Hoff representative at 1-888-ASH-PARTS.

www.a-s-h.com 1.888.ASH.PARTS

MAC™ is a trademark of Magaldi Power S.p.A.

Allen-Sherman-Hoff is a division of Diamond Power International, Inc.

MAC™ Systems are supplied in the United States by Allen-Sherman-Hoff under a license
from Magaldi Power S.p.A.

This information contain herein is solely for informational purposes and is not offered,
nor should be construed, as a warranty or contractual obligation. Diamond Power

Magaldi Ash Cooler

International, Inc. Reserves the right to make design or material changes without notice. ™

Dry Bottom Ash System

©2005 Diamond Power International, Inc. All rights reserved. ASH-9342-0805-00