CONSTRUCTION AND WORKING OF COAL HANDLING PLANT

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PRESENTED BY
Shrikant S. Khating

INDEX
Introduction. Availability of Coal in India. Transportation of Coal. Analysis of Coal. General Layout of CHP. CHP Auxiliary And Equipments

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INTRODUCTION
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What is CHP? CHP (C- Coal, H- Handling, P- Plant) Which properly handles the coal from its receipt to transferring it to bunkers. Objective of CHP : To

supply the quanta of processed coal to bunkers of Coal mills for Boiler operation. To Stack the coal to coal yard.
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AVAILABILITY OF COAL IN INDIA.

Mostly E and F grade coal used in India. Blending Is Done To get Average D Grade.

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Grade

C.V. ( K Cal / Kg. ) > 6200 5601-6200 4941-5600 4201-5940 3361-4200 2401-3360

% Ash + Moisture

A B C D E F

19.57 19.57 - 23.97 23.92 - 28.69 28.69 - 34.05 34.06 - 40.14

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40.14 - 47.10

TRANSPORTATION OF COAL
5 ways of Transportation.

Best and Cheap facility at Doorstep

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1. Railways. 2. Ropeways. 3. Roadways. 4. waterways. 5. Airway.

Available only for TPS nearer to coal mines

Fear of thief

waterway may not be possible till TPS and Problem of recalling arises if coal dip in water Have to build Runway near TPS which is very costly.

BY RAIL WAY

80-90% of the requirement is fulfilled by this way.

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Demurrage calculations on coal Rakes: We receive the coal wagons in the form of rakes (55-60 wagons in each rake).

Free time normally 7 hrs. from Receipt of coal. Free time is calculated from the receipt of written intimation of coal rakes from MAHAGENCO to the railway. Rate of demurrage is Rs.100 / wagon / hr.
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ANALYSIS OF COAL
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Chemical Analysis of Coal:Sample of coal is randomly collected from each rake and detailed chemical analysis, calculation of calorific value is carried out and is confirmed whether it is as per agreement with the coal mines or not.

GENERAL LAYOUT OF CHP

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Wagon Tippler
Hopper

Crusher House
Surge Hopper

Feeder Conv. Belts

Vibrating Screens

Crushers

Tripper Trolley
Bunkers
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CHP Auxiliaries
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OPERATIONAL CYCLE
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Bunkering Cycle

Stacking Cycle

Reclaiming Cycle
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BUNKERING CYCLE
From W/T
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Crusher House
Surge Hopper

Vibrating Feeder

Crusher

Bunkering Belts

Bunkers

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STACKING CYCLE
From W/T Crusher House
Coal Is not required if bunker is full or Due any maintenance
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By-Passed Coal

Bunkering Belts

Stacking Belts

Bunkers

Crushed Yard

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RECLAIMING CYCLE
From W/T
If Outer Supply of coal Is Not Present
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Crusher House NonCrushed Yard Reclaiming Belts

Stacked Coal

Bunkering Belts

Bunkers

Crushed Yard

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WAGON TIPPLER

These are used to unload the coal wagons into coal hoppers in very less time (e.g. 20 wagons/hr. or more). Weighing of coal is carried out at wagon tippler.

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Normally 55-60 metric ton of coal come in each wagon.

Wt of the coal =Wt. of loaded wagon Wt. of empty wagon

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WAGON TIPPLER DRIVE SYSTEM

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Motor

Thruster Brake

G/B

Pinion Spur Gear

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GENERAL LAYOUT OF W/T

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Wagon tippler

Mesh of 250 mm * 250 mm

Hopper

Vibrating Feeder

Conveyor Belt
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To crusher House

EQUIPMENT USED IN W/T

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Water Sprinkler System. Dust Extraction System.

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CONVEYOR BELT SYSTEM

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Construction of Conveyor Belt Conveyor Belt Drive System Counter Weight Idlers Protection System

Interlocking Magnetic Separator

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CONSTRUCTION OF CONVEYOR BELT

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Synthetic rubber. 4 ply means 4 nylon net in between 2 mm thick rubber coating is used. At KTPS belt of 1000 mm width is used. Width varies from 500 mm -1400 mm.
Strength = 600 N 1000 mm

Net

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CONVEYOR BELT DRIVE SYSTEM

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Fusible plug

Head End Pulley

Motor

G/B

Fluid Coupling

Filled with 3/4th oil

Tail End Pulley Belt Speed oSpeed before crusher 2.4 m/sec oSpeed After Crusher 2.7 m/sec

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COUNTER WEIGHT
Idlers Head End Pulley Conveyor Belt
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Tail End Pulley

Return Idlers Take-up Pulley Railing Counter Weight

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IDLERS

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Carry Side

Return Side

Self Alignment

Impact

Return Roller

Return Adjustment Roller

( Installed after every 25m )

Below Discharge chute ( rubber coating )

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ANGLE OF IDLERS
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Angle 20

Merits No middle idler is overloaded

Demerits More Coal Derailed

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Coal not Derail.

Middle idler is overloaded

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PROTECTION SYSTEM
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Interlocking is used for safety purpose. If any belt fails all other belts stop working which are interconnected.

Magnetic Separator is used to remove metal particle from coal conveyed through conveyor belt for improving boiler efficiency.

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CRUSHING MECHANISM IN CHP

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Three Stage Crushing System is used in Plant.

1.Double Roll Crusher 2.Rotary Breaker Crusher 3.Impact Crusher

W / T No.4
600 mm

DRCR
250 mm Stage 1

RBCR
80 mm Stage 2

Impact

Stage 3

20-25 mm

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DOUBLE ROLL CRUSHER ( DRCR )

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Roller

Teeth

300 mm

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ROTARY BREAKER CRUSHER ( RBCR )

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250 mm Striking Plate Hole of diameter 100 mm

Stone shell

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80 mm

IMPACT CRUSHER
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Coal Hammer

30 mm

Rotor

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