53-FA02111C-C-001（English）

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Drawing No.53-FA02111C -C-001

RIAU COAL FIRED STEAM POWER PLANT PROJECT

2X110MW

Preliminary Design Stage

Volume 6 Ash Handling Part

Preliminary Design Description

State class A Certificate No.: A153001315

J uly 2011 K unming

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RIAU COAL FIRED STEAM POWER PLANT PROJ ECT 2X110MW

PRELIMINARY DESIGN

1

APPROVED BY

REVIEWED BY

CHECKED BY

PREPARED BY

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Table of Content

Chapter 1 General Description.........................................................................................1

1.1 Project Summary ..................................................................................................1

1.2 Design Basis .........................................................................................................1

1.3 Major Design Principle.........................................................................................2

1.4 Original Design Data ............................................................................................2

1.5 Design Contents and Scopes ................................................................................5

1.6 Boiler Ash and Slag Quantity and Limestone Powder Consumption Quantity....5

Chapter 2 Bottom ash handling system...........................................................................7

2.1 The principle for Determination of the System....................................................7

2.2 Technical Process of Bottom Ash Handling System ............................................7

2.3 System Output and Equipment Configuration .....................................................8

Chapter 3 Limestone Powder Handling System...........................................................10

3.1 Principle of the System Determination...............................................................10

3.2 Technical Process of Limestone Powder Conveying System.............................10

Chapter 4 Ash Handling System ....................................................................................13

4.1 Principle of the System Determination...............................................................13

4.2 Technical Process of Ash Handling System .......................................................13

4.3 System Output and Equipment Arrangement.....................................................14

4.4 Selection and Arrangement of Pneumatic Ash Handling Auxiliary System ......15

Chapter 5 Water Supply System Of Ash Handling......................................................18

Chapter 6 Ash Conveyance System Of Off-site............................................................19

Chapter 7 Labor Safty And Profession Health .............................................................20

7.1 Labor Safety .......................................................................................................20

7.2 Dust Prevention ..................................................................................................20

7.3 Noise Prevention ................................................................................................20

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Chapter 1 General Description

1.1 Project Summary

The project site is located at southeast of Tenayan industry park of

Pekanbaru district of Riau Province on Sumatral island. The power plant is at

northeast side with a distance of 10 kilometers to Pekanbaru (capital city of

Riau Province), and the power plant faces coastline of Siak in north side and

adjoins with Gajah Mada Street in west side. It is located at southeast side in

Tenayan industry park.

This projects construction scale is 2430t/h high-temperature and

high-pressure parameters circulating fluidized bed boiler and 2110MW

high-temperature and high-pressure parameters condensing turbo-generating

unit. Planning capacity is 2110MW. Due to space constraints, expansion will

not be considered.

1.2 Design Basis

1The EPC contract of PLTU RIAU 2110 MW project was signed by PT

PLN(PERSERO) and Consortium PT Rekayasa IndustriHubei Hongyuan

Power Eng.Co, Ltd

2The tender documentthe addendum and the clarification document of

PLTU RIAU 2110 MW project was issued by PT PLN (PERSERO)

3The design contract of PLTU RIAU 2110 MW project was signed by

Hubei Hongyuan Power Eng.Co., Ltd and Yunnan Electric Power Design

Institute

4Technical code for designing fossil fuel power plants DL 5000-2000

5Regulation for content and depth of primary design document of fossil

fuel power plants DL/T 5427-2009

6

Technical code for designing ash handling of power plants DL/T

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5142-2002

7Boiler, steam turbine and generator, three main equipments contract for

goods and technical agreements

8The relevant Chinese laws, regulations, policies and procedures related

to the design, specifications, etc

9Indonesia's local laws, regulations, policies and relevant provisions, etc.

1.3 Major Design Principle

1.3.1 Separated fly ash and bottom ash handling system and dry ash in dry

drainage system shall be adopted for ash and bottom ash handling system. The

bottom ash handling system shall be determined in accordance with machinery

conveying schedule; fly ash handlingsystem shall be determined in accordance

with pneumatic conveying method of positive pressure and dense phase, and fly

ash and bottom ash outside shall be determined inaccordance with motor

transportation schedule.

1.3.2 Limestone powder conveying system shall be determined in accordance

with the schedule of level-one positive pressure convey to bolier.

1.3.3 Centralized compressed air station shall be set up for compressed air

system of the whole plant.

1.3.4 Sufficient margin for fly ash and bottom ash handling system shall be

remained in order to adjust to the coal quality of the Project.

1.3.5 Based on the principle of equal importance to save and development and

reasonable utilization of resources, closed cooling water shall be adopted for the

whole equipment and reused water for dry ash mixing.

1.4 Original Design Data

1.4.1 Analysis of the coal data and ash components of the Project are as shown

in following Table 1-1 and Table 1-2:

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Table 1-1 Coal analysis tables

RangeParameter

Minimum MaximumTypical

Proximated Analysis% as received

Total Moisture 25 40 35

Inherent Moisture 13.8 25 18

Ash 3.3 6 5

Volatile 27.9 40 35

Fixed Carbon 23 41 25

Specific Energy (as received)

High Heating Value (kcal/kg)3700 4700 4000

Ultimate Analysis (% dry ash free

Carbon 65 80 68.2

Hydrogen 3 5.9 5.7

Nitrogen 0.54 1.2 1.13

Oxygen 12 30 23.17

Sulfur 0.13 2.2 1.8

Table 1-2 Ash analysis tables

RangeParameter


SiO2 2 60 34

Al2O3 3 52 6

Fe2O3 4.7 52.5 39TiO3 0.02 4.1 0.48

Mn3O4 0.2 8.8 2

CaO 0.8 27.7 10

MgO 0.02 32.6 5

Na2O 0.05 4.12 0.17

K2O 0.1 2.4 1.3

P2O5 0.03 0.8 0.51

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RangeParameter


SO3 0.2 24.6 1

Ash Fusion Temperature Reducing Reducing Reducing

I.D.Tdefromation 1050

S.T.(softening) 1100

H.T.(hemispherical) 1150

F.T.(fluid) 1200

Ash Fusion Temperature Oxidizing Oxidizing Oxidizing

Slagging and Fouling Index Medium

Hardgrove Grindability Index (HGI) 40 65 50

1.4.2 Utilization hours of the machine unit

The annual utilization hours of the boiler of the Project is calculated as

7008 hours, and daily utilization hours as 20 hours.

1.4.3 Distribution ratio of bottom ash and fly ash

The distribution ratio of bottom ash and fly ash is 20:80 according to the

data provided by boiler factory.

1.4.4 Slagging methods of the boiler

Roller-type bottom ash cooler and continuous slagging method is adopted

for boiler bottom ash cooling equipment.

1.4.5 Precipitator type and efficiency

Electrical precipitator is adopted for the Project with an efficiency of

99.7%.

1.4.6 Ash Yard

The ash storage yard is located at south side of the plant. Dry ash removal

process is adopted for the operation of the ash storage yard and ash and slag will

be transported to ash storage yard for storage by trucks.

The ash storage yard is on the right bank of Siak River with a flat and open

area, and low mountains and hills are separately distributed at west side with a

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distance of 1km to the west side of the yard. The geomorphic unit type is flood

plain and swamp which is formed by fluvial outwash and the elevation is

normally between 2.5m~3.0m according to the local elevation system of

Indonesia. The land is covered by dense vegetation and the ash storage yard is

now mainly covered by weeds and pteridophyte plants after the original palm

land has been cut down without preservation. Affected by Siak River, a few

surface water systems which exist in a form of small stream or brook with small

water volume develop in and around the yard. There are no buildings or

structures in the yard.

1.5 Design Contents and Scopes

The design contents of the Project are bottom ash handling system, fly ash

handling system, limestone powder conveying system and auxiliary system; and

the design scopes are as follows: all the equipment, pipelines, pipe fittings and

valves of the fly ash handling system from the outlet of precipitator ash hopper

to the outlet of ash discharge equipment in fly ash bin; all the equipment,

pipelines, pipe fittings and valves of the bottom ash handling system from the

outlet of boiler slag cooler to the outlet of unloading equipment of bottom ash

bin; and all the equipment, pipelines, pipe fittings and valves of the limestone

powder conveying system from the loading of limestone powder in bags to

limestone silo then to boiler furnace.

1.6 Boiler Ash and Slag Quantity and Limestone Powder Consumption

Quantity

The boiler ash quantity and limestone powder consumption quantity are

shown in the following Table 1-3 and Table 1-4:

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Table 1-3 Ash quantity

Hourly ash quantityt/h Daily ash quantityt/d Yearly ash quantityt/aITEM

Fly ash Bottom ash Total Fly ash Bottom ash Total Fly ash Bottom ash Total

1

430 t/hboiler 7.327 1.832 9.159 146.54 36.64 183.18 51348 12839 64186

2430t/h

boiler 14.654 3.664 18.318 293.08 73.28 366.36 102695 25677 128372

Table1-4 Limestone powder quantity

ITEM Hourly quantityt/h Daily quantityt/d Yearly quantityt/a

1430 t/h

boiler5.744 114.88 40254

2430 t/h

boiler 11.488 229.76 80508

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Chapter 2 Bottom ash handling system

2.1 The principle for Determination of the System

Because the CaO and CaSO4 content of the bottom ash discharged by CFB

is very high, so the waterpower handling methods shall not be adopted.

Therefore, mechanical handling methods is adopted for the bottom ash handling

system of the Project.

2.2 Technical Process of Bottom Ash Handling System

Because the CFB contains limestone for burning, so the CaO content in

bottom ash is high and the bottom ash owns the characteristics of radiation,

expansion, hardening and alkalinity when meets water, so waterpower handling

methods shall not be adopted. And mechanical handling method is more

adjustable to the change of the slag quantity with higher technology and lower

energy consumption, so mechanical conveying system is preliminarily adopted

for the bottom ash handling system of the Project.

Mechanical bottom ash handling system diagram refer to 53-FA02111C

-C-002.

Process flow diagram shown below:

Bottom ash cooler

En-masse scra er conve er

Bottom ash bin

Pu mill

Ash ard

Bucket elevator

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Two bottom ash coolers shall be set up for each boiler and their slagging outlets

are parallel on the same line. One en-masse scraper conveyer is set up below the

cooler to convey the discharged slag into bucket elevator after the bottom ash is

collected, and the bucket elevator then conveys them into bottom ash bin. One

discharge openings shall be set up below the bottom ash bin, and one double

paddle blender shall be set up at the same time. Bottom ash shall be humidified

by the double paddle blender and then conveyed to ash yard .

One bottom ash bin of steel structure with a diameter of 5m with an

available volume of 25m3

shall be set up for each boiler and close to the boiler,

and it can store a quantity of bottom ash for 15 hours under the design working

conditions of the boiler. In order to make bottom ash discharge convenient and

smooth, one bucket wall vibrator shall be set up.

2.3 System Output and Equipment Configuration

One unit of bottom ash handling system shall be set up for each boiler, and

one en-masse scraper conveyer and one bucket elevator shall be set up for eachunit of bottom ash handling system. The system output is 200% of boiler bottom

ash volume under design working conditions, that is 4t/h, to meet the

requirements of operation and accidental overhaul. The main equipment

configuration of bottom ash handling system is shown as following in Table

2-1:

Table 2-1 The main equipment configuration of bottom ash handling system

NO. NAME MODEL AND SPECIFICATION UNIT QTY. REMARKS

1 Steel bottom ash bin 5 m Available volume:25m3

Set 2

2 En-masse scraper conveyer Q4t/h L25m N=4.5KW Set 2

3 Bucket elevator Q4t/h L18m N=5.5KW Set 2

4 Arrester S25m2

Set 2

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5Vacuum and pressure relief

valve508 Set 2

6 Vibrator 0.75KW Set 12

7 Double paddle blender Q=100t/h N=11+2.2KW Set 2

8 Vertical sewage pumpQ=26.6m

3/h P=0.24MPa

N=5.5 KWSet 2

Bottom ash conveying equipment layout of boiler refer to 53-FA02111C

-C-006.

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Chapter 3 Limestone Powder Handling System

3.1 Principle of the System Determination

First level pneumatic conveying method is adopted for limestone powder

handling system of the Project.

3.2Technical Process of Limestone Powder Conveying System

Limestone powder of the Project comes from two ways: one is purchased

finished powder in bags (grain size distribution meets the requirements of the

boiler factory),the finished powder will be sent into bag breaking machine by

fork-lift truck and then into limestone powder silo by bucket elevator; the other

one is purchased bulk limestone powder (grain size distribution meets the

requirements of the boiler factory), and after it is sent to limestone powder

underground hopper by the tipper, it will be sent into bucket elevator by screw

conveyer and then into limestone powder silo through bucket elevator.

First level pneumatic conveying method shall be adopted for conveying of

the limestone powder from limestone powder silo to boiler. This method isrelatively simple, and with fewer intermediate links and a high reliability of

system operation.

Limestone powder handling system diagram refer to 53-FA02111C -C-004.


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One limestone powder silo in steel structurer shall be set up for each boiler

and located close to the boiler. Each steel structurer silo with a diameter of 5m

with an available volume of 65m3 and a capacity for 12-hour consumption of

the limestone powder necessary for the each boiler under design working

conditions. One limestone powder conveyor shall be set up below each silo to

convey limestone powder to boiler. The output of limestone powder handling

system shall be continuous and adjustable, and the maximum output of the

limestone powder handling system shall not be lower than 150% of the design

limestone powder consumption of a single boiler, i.e. the system output shall be

9t/h .

Vacuum and pressure relief valve and arrester shall be set up at the top of

limestone powder silo and aeration device at the bottom of it in order to make

limestone powder discharge more convenient. One discharge opening shall be

set up below each limestone powder silo and one unit limestone powder

conveyor shall be set up below each discharge opening. Compressed air for

Limestone powder

in bag

Fork-lift

truck Bag-breaking machine

Bulk limestone

powder Underground hopper Screw conveyer

Bucket

elevator

Limestone powder silo Pressure vessel conveyer Screw feeder

Boiler

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limestone powder conveying and aeration air all comes from compressed air

system of the whole plant and air tank shall be set up beside the limestone

powder silo.

The main equipment configuration of limestone handling system is shown

as following Table 3-1:

Table 3-1 The main equipment configuration of limestone handling system


1 Steel limestone silo 5 m Available volume:65m3

set 2

2 Steel underground hopper Available volume:20m3

set 2

3 Bag-breaking Machine Q15t/h N=5.5KW set 2

4 Bucket elevator Q15t/h L22m N=7.5KW set 2

5 Pressure vessel conveyer V=1.2m3

set 2

6 Screw conveyer Q=0~15t/h N=4.5kW set 4Frequency

control

7 Arrester S40m2

set 2

8Vacuum and pressure relief

valve

SSF508 set 2

9 Round aeration stone 120 set 12

10 Electric air heater N=30KW set 2

11 Fork-lift truck G1t set 3

Layout for equipment of limestone conveying refer to 53-FA02111C

-C-008.

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Chapter 4 Ash Handling System

4.1 Principle of the System Determination

The pneumatic conveying mode of positive pressure and dense phase is

adopted for fly ash handling system of the Project.

4.2 Technical Process of Ash Handling System

The pneumatic conveying mode of positive pressure and dense phase is

with advanced technology, low conveying speed, and small air consumption as

well as high ratio of ash and air conveyed, low energy consumption, low

attrition and simple and reliable system, and it also has excellent operation

performance and obvious advantages in environmental cleaning, appearance

and arrangement, and operation maintenance. Therefore, pneumatic conveying

mode of positive pressure and dense phase shall be preliminarily adopted for fly

ash handling system of the Project.

Dry ash collected by ash bucket of precipitator and ash bucket below air

preheater shall be conveyed to fly ash bin by the compressed air. And dry ash infly ash bin shall be sent to ash yard after stirring by the wet-type blender.

Pneumatic ash handling system diagram refer to 53-FA02111C -C-003.


Eight ash hoppers shall be set up for each boiler precipitator and every two

Precipitator ash hopper Compressed air

Pressure vessel conveyer

Fly ash bin

Pu mill

Ash stora e

Air preheater hopper

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ash hoppers are in a row and in total 4 rows. One ash conveyor shall be set up

for each ash hopper. Two ash pipelines shall be set up for fly ash handling

system, and one ash pipeline shall be set up for the first electric field of the

precipitator and the second, third and fourth electric fields jointly use one ash

pipeline. Two ash hoppers shall be set up for each boiler air preheater and the

ash of air preheater hoppers shall be conveyed to the second electric field

pipeline through one ash pipeline, and the ash shall be conveyed into coarse ash

bin or fine ash bin by the compressed air.

Two fly ash bins of steel structure shall be set up for the two boilers. Fly

ash bins shall be arranged close to chimney and maximum conveying distance is

about 200m.

The diameter of each fly ash bin shall be 6m and available volume shall be

120m3, and the total capacity of two fly ash bins shall store 12-hour boiler

discharged ash volume provided that the two boilers use the design coal. One

discharge openings shall be set up below each fly ash bin, and one double

paddle blender with an output of 100t/h shall be set up. Fly ash shall behumidified by the double paddle blender and then conveyed to ash yard .

4.3 System Output and Equipment Arrangement

One unit of pneumatic ash handling system shall be set up for each boiler.

The design system output shall be 150% of the ash volume discharged by a

single boiler under its maximum evaporation capacity and burned with design

coal, that is, the system output shall be 11t/h in a continuous operation mode.

The main equipment configuration of fly ash handling system is shown in the

following Table 4-1:

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Table 4-1 The main equipment configuration of ash handling system


1 Steel fly ash silo 6 m Available volume:120m3 set 2


set 4


set 12


set 4

5 Arrester S=60m2

set 2

6Vacuum and pressure

relief valveSSF508 set 2

7 Double paddle blender Q=100t/h N=11+2.2KW set 2

8 Electric hoist G=1t H20m N=1.5+0.4KW set 1

9 Round aeration stone 120 set 12

Layout for piping and equipment of fly ash silo refer to 53-FA02111C

-C-009.

4.4 Selection and Arrangement of Pneumatic Ash Handling Auxiliary

System

4.4.1 Aeration air system

In order to prevent moisture condensation, increase the flowability of dry

ash in ash hopper of precipitator, and make discharge process smooth, two

aeration blowers shall be set at the 0m floor below precipitator to supply

aeration air to ash hopper of precipitator and fly ash bin for gasification. Besides,

one electric heater shall be set up to heat the aeration air into 150. The

electric heater for precipitator shall be set up at 0m floor and that for fly ash bin

shall be at fly ash bin operation floor in order to save land occupation.

4.4.2 Compressed air system of the whole plant

Unified air compressor station shall be set up for the whole plant in order

to supply air for boiler, ash handling, control and chemical, and it makes various

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specialized air supply systems into an unified one and changes the defects that

there are too many spare sets of equipment, too much of equipment and various

specifications as well as the situation of separated arrangement and difficult

maintenance management.

The technically matured oil-free screw type air compressor is adopted for

the air supply equipment and corresponding treatment equipment post air

processing is also adopted in order to prevent the blocking of the ash conveying

pipeline caused by compressed air with water or oil. Three oil-free screw type

air compressors are set up in air compressor station with two in operation and

another one for standby; meanwhile three combination compressed air dryers

and four air tanks of 10m3

are also equipped in order to make sure that the air

quality is good and the air supply is stable.

4.4.3 Cleaning system

Hydraulic cleaning system as well as sewage tank shall be adopted in fly

ash bin and bottom ash bin area. The waste water shall be conveyed into

coal-containing sewage tank through sewage pump and reused after treatment inorder to save water and enhance the clean and harmonious production level. The

main equipment configuration of ash handling auxiliary system is shown in the

following Table 4-2:

Table 4-2 The main equipment configuration of ash handling auxiliary system


1 Screw type air compressorQ=27m

3

/min P=0.8Mpa

N=160kWset 3

Shared device

of whole plant

2Combination compressed

air dryersQ=30m

3/min P=0.8Mpa N=6kW set 3

3 Air Tank V10m3

P=1.0MPa set 4

4 Roots blower Q=10m3/min P=78kPa N=30kW set 2

5 Electric air heater N30Kw set 4

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6motor single-track

bridge crane

G5t L=10.5m H6m

N7.5+0.8+0.4KWset 1

7 Vertical sewage pumpQ=26.6m

3/h P=0.24MPa

N=5.5 KWset 2

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Chapter 5 Water Supply System Of Ash Handling

Water for ash handling system shall be provided by thermomechanic and

discharge major. Cooling water for equipment shall be provided by

thermomechanic major and mixing water shall be reused water provided by

discharge major. The water consumption equipment is shown in the following

Table 5-1:

Table5-1 List of water consumption equipment of ash handling system

NO. NAMECONSUMP

TIONm3/hWATER QUALITY

PRESSURE

MPaWATER WAY

1Screw type

air compressor24

closed cycle cooling

water0.3~0.5

continuous

2Combination

compressed air dryers12

closed cycle cooling

water0.3~0.5

continuous

3 Double paddle mixer 40 re-use of water 0.2~0.3interrupt

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Chapter 6 Ash Conveyance System Of Off-site

The ash shall be conveyed by tip truck to ash yard for storage . Relevant

description of ash yard is in introduction related to hydro-structure major.

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Chapter 7 Labor Safty And Profession Health

7.1 Labor Safety

Protective cover shall be installed for all the operating machines in ash

handling system as well as outside the couplers of all the operating machines in

order to prevent potential machinery injury. Safety rails shall be installed in ash

bin, at the top of bottom ash bin and on operation platform in accordance with

specifications; rails and cover plates shall be set up at dangerous sites where are

of a potential of falling down, such as platform, walking board (footpath),

hatchway, hoisting hole, gate well and pool sides. Emergency stopping switch

shall be set up for ash handling control system to prevent accidents due to

mistaken operation of turning on or off the equipment.

Heat insulation shall be conducted for electric air heater and aeration

pipelines succeeding it in order to prevent scalding.

7.2 Dust Prevention

Arresters are set up for fly ash bin and at the top of bottom ash bin in orderto make sure the dust content of the discharged air outside the ash bin can meet

the environmental protection requirements and the discharged exhaust gas meet

relevant standards of national environmental protection department and to

reduce environmental pollution; reused water shall be used to wash fly ash bin

and bottom ash bin area in ground cleaning work and the water after being used

shall be collected and conveyed to coal-containing waste water pool for

treatment in order to enhance the clean and harmonious production level of

bottom ash bin and fly ash bin.

7.3 Noise Prevention

During the selection of the equipment for ash handling system, it is

required that the noise level shall not be greater than 85 dB at the point one

meter away from the equipment (A). Sound insulation and absorbing measures

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in architectural design for each control room shall be considered, i.e. installation

of sound isolation room, sound absorbing wall and celling,etc. Main working

and living areas shall be far away from high noise source in order toreduce the

harm. Sound isolating measures as well as cold-proof and cooling protection

measures such as the installation of air conditioners shall be adopted outside the

fly ash bin and bottom ash bin operation room.

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