Abstract: Using the material balance algorithm, the ash storage capacity of the large ash hopper is calculated by calculating the ash input and discharge capacity of dust collector. Relying on monitoring data such as conventional sensors, real-time monitoring of ash content in large ash hoppers can be achieved. Analysis is carried out on the error of the ash volume data of material of large ash hopper, and error control methods are proposed. Linear programming models for ash hopper level warning, transfer vehicle configuration, and special emergency scenarios are established and solved. The research results show that the safe operation strategy for large ash hopper based on material balance algorithm and compound linear programming is effective and feasible.