coal handling & transportation

COAL HANDLING SYSTEM

Specifications

Coal req for 600 MW 402 TPH

Working Hrs of CHS 16 Hrs

Rated system capacity 1400 TPH

Crushed coal storage capacity 21 Days

Stored size (-)25mm

Transportation through Trucks

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Unloading from port to

plant

Receiving & Feeding to

crusherStacking Reclaiming Blending Bunker

feeding

CHS – Flow Chart

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Coal size -25mm

Coal size -300mm

Belt conveyor Belt conveyor

Bunkers

Trunk conveyorTrunk conveyor

Metal detector (8A\8B)Metal detector (8A\8B)

Inline Magnetic Separator (9A\9B)Inline Magnetic Separator (9A\9B)

Travelling TripperTravelling Tripper

Inline conveyor scale (9A\9B)Inline conveyor scale (9A\9B)

Crusher

Belt feederBelt feeder

Stock pileStock pileTrunk conveyorTrunk conveyor SCR (Stacking)SCR (Stacking)

SCR (Reclaiming)SCR (Reclaiming)

Trucks (ROM coal)Trucks (ROM coal) Track hopperTrack hopper

Paddle feederPaddle feeder

ILMS (BCN3A\3B)ILMS (BCN3A\3B)

ScreenerScreener

Belt conveyorBelt conveyor

Direct feeding

Bottom opening broad gauge rail

(BOBRN) Wagons through track hopper

Sea borne coal handling system

By trucks ie., unloading by truck tripplers

or through track hopper

COAL UNLOADING METHODS

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Single truck capacity (40-60)T No of trucks req per hour 35 Trucks operation time per day 16hr

TRUCK

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75m length.

One rake storage capacity.

RCC construction with TISCRAL liners of 20 mm

thickness.

Provision for laying railway track on track hopper.

TRACK HOPPER

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Install under the track

hopper .

4 nos. ( 2 W + 2 S ).

Capacity 800 TPH .

PADDLE FEEDER

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Rotary discharge type

Hydraulic Driven

Vibrating Grizzly type screens. 1 working + 1 Stand by Each 1400 TPH capacity. Screening Size (-)25 mm

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SCREEN

1 working + 1 Stand by

Each 1400 TPH capacity.

Ring Granulator Type Crusher.

Lump coal size - 300mm

Crushed size - 25 mm

Crusher

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One working + one stand by Reversible rail mounted type. Operating on bi-directional conveyor ( 11&12). Stacking & Reclaiming Capacity 1400 TPH. Length of the Boom conveyor 43 m. Track gauge length 7 m. During Reclaiming 50 discharges of bucket

wheel per minute

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STACKER CUM RECLAIMER

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UNI DIRECTIONAL BI-DIRECTIONAL

Belt sway less and controllable

Power consumption is high

Belt sway is high

Power consumption is low

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** Though the initial cost of the bi-directional conveyor is high, it is been selected . Because the power consumption is less..

Trunk conveyor length 700m.

TRUNK CONVEYOR SELECTION

Trapezoidal Triangular

I. Pile formed by slewing of stacker

II. Boom conveyor length 43 m

III. More amount of coal can be stored

IV. High cost of SCR

I. Formed by Single point discharge

II. Boom conveyor length 30m

III. Less in amount

IV. Low cost of SCR

Proposed cross section ------------ TRAPEZOIDAL

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Stock Pile Comparison

40 M 500 M

8.75

M

Crushed coal storage capacity 21 days for 2*600 MW units

Total stock req including PLF 3,44,433 Tonnes.

No of piles 4

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STOCK PILE350

PARMETERS DESIGN COAL(50:50)

SM COAL INDIAN COAL

Proximate Analysis(ARB) In % In % In %

Ash 20.68 2.04 39.31

VM 27.59 33.98 21.20

FC 28.58 28.16 28.99

Sulphur 0.44 0.29 0.59

HGI 47 47 45

GCV in Kcal/Kg 3932 4134 3729

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WHY WE GO FOR BLENDING??

Blending = 50% SM coal + 50% high ash Indian coal .

Coal stored in different stockpiles would be blended by

reclaiming coal from different stock piles and

conveying the same on the common succeeding

conveyors.

Flow would be divided by flow dividers at the head

end of the trunk conveyors.

Not a homogeneous mix.

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Blending of coal

Rated capacity 1400 TPH.

Width 1400 mm.

Troughing Angle 350

Belt Speed 2.8 m/s.

With Fire retardant grade cover

Motor capacity 1.25 of the rated

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Belt conveyors

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BELT PULLEY

IDLERS

LOAD CELLS

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Conveyor Gallery

Walkways

Conveyor tunnel

Brakes

Belt Cleaners

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Belt Conveyor – Accessories

BrakesElectro-hydraulic thrustor brakes of fail safe design to adjust

the coasting time of the conveyors in order to prevent spillage of material

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V type internal belt cleaner

Sprung blade type belt cleaner

External belt cleaner

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BELT CLEANERS

ILMS Remove tramp iron & other magnetic

materials provided @ conveyors BCN- 3A/B & 9A/B

Metal detectorDetect non magnetic metal pieces & heavy

iron pieces Provided on BCN 9A/B

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@ BCN 1A/1B Measure & control of coal arrival

@ BCN 9A/9B Measure the amt of coal feed to

the boiler bunker.

In SCR Measure the coal avail in the

stock yard & to know the rate of

stacking & reclaiming

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METERING OF COAL

@ BCN 1A/1B Measure & control of coal arrival

@ BCN 9A/9B Measure the amt of coal feed to

the boiler bunker.

In SCR Measure the coal avail in the

stock yard & to know the rate of

stacking & reclaiming

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METERING OF COAL

@ BCN 1A/1B Measure & control of coal arrival

@ BCN 9A/9B Measure the amt of coal feed to

the boiler bunker.

In SCR Measure the coal avail in the

stock yard & to know the rate of

stacking & reclaiming

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METERING OF COAL

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Dry fog Compressed air + water.

Used to suppress and control dust in crusher

houses, junction towers and transfer houses.

principle of agglomeration.

Dust + fog droplets Settle down.

DUST SUPPRESSION

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THANK U…

Wagon tipplers for unloading BOX-N wagons.

Track hopper for receiving BOBR-N wagons .

Marshalling yard and railway track on the track hopper.

Four additional piles with two combined stacker cum reclaimer.

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FUTURE PLANS

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