WORKING AND CONSTRUCTION OF COAL HANDLING PLANT

CONSTRUCTIONAND WORKING OFCOAL HANDLING PLANT

7/21/20151indexIntroduction.Availability of Coal in India.Transportation of Coal.Analysis of Coal.General Layout of CHP.CHP Auxiliary And Equipments7/21/20152IntroductionWhat 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.7/21/20153Availability of Coal In India.Mostly E and F grade coal used in India.Blending Is Done To get Average D Grade.

7/21/20154GradeC.V. ( K Cal / Kg. )% Ash + MoistureA> 620019.57B5601-620019.57 - 23.97C4941-560023.92 - 28.69D4201-594028.69 - 34.05E3361-420034.06 - 40.14F2401-336040.14 - 47.10Transportation of Coal5 ways of Transportation.

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

7/21/20155Available only for TPS nearer to coal minesHave to build Runway near TPS which is very costly.waterway may not be possible till TPS and Problem of recalling arises if coal dip in waterBest and Cheap facility at DoorstepFear of thiefBy Rail Way80-90% of the requirement is fulfilled by this way.

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.

7/21/20156Analysis of CoalChemical 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.

7/21/20157General Layout Of CHP7/21/20158Wagon TipplerCrusher HouseBunkersTripper TrolleyConv. BeltsVibrating ScreensCrushersFeederSurge HopperHopper87/21/20159Operational Cycle7/21/201510Bunkering Cycle7/21/201511BunkersFrom W/TBunkering BeltsSurge Hopper Vibrating FeederCrusher HouseCrusher11Stacking Cycle7/21/201512BunkersStacking BeltsCrushed YardFrom W/TCrusher HouseBunkering BeltsBy-Passed CoalCoal Is not required if bunker is full or Due any maintenance 12Reclaiming Cycle7/21/201513BunkersReclaiming BeltsCrushed YardNon-Crushed YardFrom W/TCrusher HouseBunkering BeltsIf Outer Supply of coal Is Not PresentStacked Coal13Wagon TipplerThese 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.

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

7/21/201514Wt of the coal =Wt. of loaded wagon Wt. of empty wagonWagon Tippler Drive System7/21/201515MotorPinionSpur GearThruster BrakeG / BWagon tipplerMesh of 250 mm * 250 mmHopperVibrating FeederConveyor BeltTo crusher HouseGeneral Layout Of W/t7/21/201516Equipment Used In W/TWater Sprinkler System.Dust Extraction System.

7/21/201517Conveyor Belt SystemConstruction of Conveyor BeltConveyor Belt Drive SystemCounter WeightIdlersProtection SystemInterlockingMagnetic Separator7/21/201518Construction of Conveyor BeltSynthetic 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. 7/21/201519NetStrength = 600 N1000 mmConveyor Belt Drive System7/21/201520MotorG / BFluid CouplingFilled with 3/4th oilFusible plugHead End PulleyTail End PulleySpeed before crusher 2.4 m/secSpeed After Crusher 2.7 m/secBelt SpeedCounter Weight7/21/201521Return IdlersIdlersCounter WeightHead End PulleyTail End PulleyConveyor BeltRailingTake-up PulleyIdlers7/21/201522Carry SideReturn SideSelf AlignmentImpactReturn RollerReturn Adjustment Roller( Installed after every 25m )Below Discharge chute( rubber coating )35Angle Of Idlers7/21/201523AngleMeritsDemerits20No middle idler is overloadedMore Coal Derailed35Coal not Derail.Middle idler is overloaded

Protection SystemInterlocking 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.7/21/201524Crushing Mechanism In CHPThree Stage Crushing System is used in Plant.1.Double Roll Crusher2.Rotary Breaker Crusher3.Impact Crusher7/21/201525W / T No.4DRCRRBCRImpact250 mm80 mm600 mm20-25 mmStage 1Stage 2Stage 3Double Roll Crusher ( DRCR )7/21/201526TeethRoller300 mmRotary Breaker Crusher ( RBCR )7/21/201527Striking PlateHole of diameter 100 mm250 mm80 mmStone shellImpact Crusher7/21/201528Hammer30 mmRotorCoalThank You.7/21/201529