coal handling division anpara

38
Preface This Project Report entitled “COAL HANDLING PLANT” has been prepared in fulfilment of Industrial Training to be carried out in second year of our four year B.TECH course. For preparing the Project Report, I have visited Anpara Thermal Power Station underUttarPradeshRajyaVidyutUtpadan NigamLtd.during the suggested duration for the period of 28 days, to avail necessary information. The blend of learning and knowledge acquired during our practical studies at the company is presented in this Project Report. The rationale behind visiting the power plant and preparing this Project Report is to study electrical overview related to power generation and its auxiliaries in thermal power plant. We have carried out this training under well experienced and highly qualified engineers of ATPS, UPRVUNL of various departments. We have taken the opportunity to explore the coal handling division(C.H.D.),its use, necessity in power plant and maintenance of various equipment used for power generation and controlling the numerous process of power generation. I have tried our best to cover all the aspects of power plant specially stacking and their brief detailing in this project report. All the above mention topic will be presented in the following pages of this report. The main aim to carry out this project is to familiarize ourselves

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Page 1: COAL HANDLING DIVISION ANPARA

PrefaceThis Project Report entitled “COAL HANDLING PLANT” has been prepared in fulfilment of Industrial Training to be carried out in second year of our four year B.TECH course. For preparing the Project Report, I have visited Anpara Thermal Power Station underUttarPradeshRajyaVidyutUtpadan NigamLtd.during the suggested duration for the period of 28 days, to avail necessary information. The blend of learning and knowledge acquired during our practical studies at the company is presented in this Project Report.

The rationale behind visiting the power plant and preparing this Project Report is to study electrical overview related to power generation and its auxiliaries in thermal power plant.

We have carried out this training under well experienced and highly qualified engineers of ATPS, UPRVUNL of various departments. We have taken the opportunity to explore the coal handling division(C.H.D.),its use, necessity in power plant and maintenance of various equipment used for power generation and controlling the numerous process of power generation. I have tried our best to cover all the aspects of power plant specially stacking and their brief detailing in this project report.

All the above mention topic will be presented in the following pages of this report. The main aim to carry out this project is to familiarize ourselves with the real industrial scenario, so that we can relate with our engineering studies.

Page 2: COAL HANDLING DIVISION ANPARA

AcknowledgementI take this opportunity to express my profound gratitude and deep regards toEr. SURYA PRAKASH PAL Asst.Engineer for his exemplary guidance, monitoring and constant encouragement throughout the course of this project. The blessing, help and guidance given by him time to time shall carry me a long way in the journey of life on which I am about to embark.

I also take this opportunity to express a deep sense of gratitude to Er.A. S. MISHRA Executive Engineer CHD-I Anpara Thermal Power Station, UPRVUNL for their cordial support, valuable information and guidance, which helped me in completing this task through various stages.

I am also thankful to Er. NIKHIL CHATURVEDI Executive Engineer HRD &Trg. Division for providing me opportunity to carry out my vocational training in ATPS.

I am obliged to staff members of Anpara Thermal Power Station, UPRVUNL for the valuable information provided by them in their respective fields. I am grateful for their cooperation during the period of my assignment.

Lastly, I thank almighty, my parents, sister and friends for their constant encouragement without which this assignment would not be possible

RAJAT VERMA

B.tech (Elect.Engg) IIIrdYear

Page 3: COAL HANDLING DIVISION ANPARA

ANPARA THERMAL POWER STATIONThe Anpara Power Plant is located near village Anpara on the bank of Rihand reservoir in the district of Sonebhadra (Uttar Pradesh). It is about 34 km from Rihand Dam on Pipri-Singrauli road and about 200 km from Varanasi. Varanasi is connected by air/rail and road route from other major cities.

All the units of Anpara TPS are coal-fired thermal power plants, having a total generating capacity of 1630 MW and consists of following units –

StageUnits No.

Installed Capacity

Derated Capacity

Original Equipment

Manufacturers

'A' TPS

1 210 MW 210 MWM/s Bharat Heavy

Electricals Ltd.

2 210 MW 210 MWM/s Bharat Heavy

Electricals Ltd.

3 210 MW 210 MWM/s Bharat Heavy

Electricals Ltd.

'B' TPS

4 500 MW 500 MWM/s Mitsubishi

Corporation, Japan

5 500 MW 500 MWM/s Mitsubishi

Corporation, Japan

Page 4: COAL HANDLING DIVISION ANPARA

Basic Needs and Overview of a Thermal Power Plant

Steam is an important medium of producing mechanical energy. Steam has the advantage that, it can be raised from water which is available in abundance it does not react much with the materials of the equipment of power plant and is stable at the temperature required in the plant. Steam is used to drive steam engines, steam turbines etc. Steam power station is most suitable where coal is available in abundance. Thermal electrical power generation is one of the major methods. Out of total power developed in India about 60% is thermal. For a thermal power plant the range of pressure may vary from 10 kg/cm2 to super critical pressures and the range of temperature may be from 250°C to 650°C.

Essentials of steam power plant equipment:-

A steam power plant must have following equipment:(a) A furnace to burn the fuel. (b) Steam generator or boiler containing water. Heat generated in the furnace is utilized to convert water into steam. (c) Main power unit such as an engine or turbine to use the heat energy of steam and perform work. (d) Piping system to convey steam and water.

A steam power plant using steam as working substance works basically on Rankine cycle. Steam is generated in a boiler, expanded in the prime mover and condensed in the condenser and fed into the boiler again. The different types of systems and components used in steam power plant are as follows:(a) High pressure boiler

(b) Prime mover

(c) Condensers and cooling towers

(d) Coal handling system

(e) Ash and dust handling system

(f) Draught system

(g) Feed water purification plant

(h) Pumping system

Page 5: COAL HANDLING DIVISION ANPARA

Figure shows a schematic arrangement of equipment of a steam power station. Coal received in coal storage yard of power station is transferred in the furnace by coal handling unit. Heat produced due to burning of coal is utilized in converting water contained in boiler drum into steam at suitable pressure and temperature. The steam generated is passed through the super heater. Superheated steam then flows through the turbine. After doing work in the turbine the pressure of steam is reduced. Steam leaving the turbine passes through the condenser which is maintained the low pressure of steam at the exhaust of turbine. Steam pressure in the condenser depends upon flow rate and temperature of cooling water and on effectiveness of air removal equipment. Water circulating through the condenser may be taken from the various sources such as river, lake or sea. Bled steam taken from the turbine at suitable extraction points is sent to low pressure and high pressure water heaters.

Air taken from the atmosphere is first passed through the air pre-heater, where it is heated by flue gases. The hot air then passes through the furnace. The flue gases after passing through boiler and super heater tubes, flow through the dust collector and then through economiser, air pre-heater and finally they are exhausted to the atmosphere through the chimney.

1. Air preheated, economizer, super heater, feed heaters.

2. Cooling water pump 14. Coal conveyor

3.Transmission line (3-phase) 15. Coal hopper

4. Unit transformer (3-phase) 16. Pulverizedfuel mill

5. Electric generator (3-phase) 17. Boiler drums

6. Low pressure turbine 18. Ash hopper

7. Condensate extraction 19. Super heater

8. Condenser. 20. Forced draught fan

9. Intermediate pressure turbine 21. Re-heater

10. Steam governor valve 22. Air intake

11. High pressure Turbine 23. Economiser

12. De-aerator. 24. Air pre

13. Feed heater 25. Precipitator

26. Induced draught fan –heater

27. Chimney Stack

Page 6: COAL HANDLING DIVISION ANPARA

Basic Operation in Thermal Power Plant

Page 7: COAL HANDLING DIVISION ANPARA

ATPS OVERVIEW3X210 MW

Page 8: COAL HANDLING DIVISION ANPARA

ABSTRACT

Many thermal power plants use coal as their fuel. To handle the coal, each

power station is equipped with a coal handling plant. The coal has to be sized,

processed, and handled which should be done effectively and efficiently. While

working in the coal handling plant the major factor which reduces staff

efficiency is the working environment i.e., dust etc. Generally all systems used

in power station coal handling plants are wet dust suppression systems.

INTRODUCTION

Coal Handling Plant (CHP) is a plant which handles the coal from its receipt to

transporting it to Boiler and store in Bunkers. It also processes the raw coal to

make it suitable for Boiler Operation.

Coal Handling Plant (CHP):-

Extent of work: - In brief we can say that receipt of coal from coal mines,

weighing of coal, crushing it to required size and transferring the quanta of coal

to various coal mill bunkers. This is the responsibility and duty of the CHP and

its staff.

Page 9: COAL HANDLING DIVISION ANPARA

CIRCUIT DIAGRAM OF C.H.P:-

Electrical equipment in C.H.P:-

1. 52 Nos. 6.6 KV JYOTI make breakers.

2. 02 Nos. INCOMERS and 02 no. VT panel.

3. 01 ISOLATER and BUS COUPLER.

4. 27 Nos. 6.6KV MOTORS.

Page 10: COAL HANDLING DIVISION ANPARA

General Working of Coal Handling Plant :-

As mentioned above, coal is brought to power station by either of three means

of coal transportation. This coal is first conveyed to primary crusher with the

help of different combination of conveyor belts and its rate of feeding is

controlled by Electro-magnetic vibrating feeders. Conveyor belt before the

crusher is provided with hanging magnets to separate ferrous materials. Stones

are picked up manually. In primary crusher, coal is first crushed to 150 mm

size. This coal is again conveyed to secondary/final crusher on belt system.

Here vibrating screens are used to feed crushers, which bypasses coal of size

more than 20 mm. In final crushers, coal is further crushed to required 20 mm

size. This sized coal is then send to bunkering belt and with the help of coal

trippers. This sized coal is finally fed to coal bunkers. This cycle is called coal

bunkering. In case bunkers are full, then available coal is stored in stock yard

with the help of stacking belts /automatic stacker cum reclaimer. This cycle is

called stacking. In emergency when coal is not available in plant by

railways/ropeways, then this stacked coal is diverted to the coal bunkers by

reclaiming conv. belts. This cycle is called reclaiming. The coal stored in

bunkers is further send to coal mill for pulverization and combustion in boiler

furnace.

Page 11: COAL HANDLING DIVISION ANPARA

GENARAL LAYOUT OF COAL HANDLING PLANT(CHP)

Page 12: COAL HANDLING DIVISION ANPARA

Availability of Coal In India:-

Mostly E and F grade coal used in India.

Blending Is Done To get Average D Grade.

Grade C.V.

( K Cal / Kg. )

% Ash + Moisture

A > 6200 19.57

B 5601-6200 19.57 - 23.97

C 4941-5600 23.92 - 28.69

D 4201-5940 28.69 - 34.05

E 3361-4200 34.06 - 40.14

F 2401-3360 40.14 - 47.10

TRANSPORTATION OF COAL:-

Railways:-coal is brought by railway wagons. One rack consists of 58 wagons.

Each wagon contains 58 MT of coal. Locos bring the wagons from the

marshalling yard and place them on wagon tippler. These wagons are then

unloaded with the help of wagon tippler. If these wagons are not unloaded in

stipulated time period (generally 7 hrs.), demurrage charges are levied by

railway department.

Coal Handling Plant Auxiliaries :-

Page 13: COAL HANDLING DIVISION ANPARA

Major auxiliaries of CHP:-

1. M.G.R. System

2. Vibrating Feeders

3. Conveyor Belts

4. Coal Crushers

5. Trippers

6. Electromagnetic Separators

7. Dust extraction systems

M.G.R:-

Merry go Round system. its a moving is used to unload the loaded coal wagon

below railway track at speed of 4 km/hr. From track hopper it goes on

conveyor belt via paddle feeder.

Vibrating Feeders:-

These are electromagnetic vibrating feeders or sometimes in the form of

dragging chains which are provided below the coal hoppers. This equipment is

used for controlled removal of coal from coal hoppers.

Conveyor Belts:-

These are the synthetic rubber belts which move on metallic rollers

called idlers and are used for shifting of coal from one place to other

places.The size of conveyor belt is of fallowing:-

CONVEYOR CAPACITY:- 2520 TON/Hr(max). 2100ton/hr(normal)

CONVEYOR WIDTH:- 1500MM.

CONVEYOR SPEED:-3.3M/SEC

LAYOUT OF CONVEYOR SYSTEM :-

Page 14: COAL HANDLING DIVISION ANPARA

TP-9 11A TP-10

11B U#3

CONV.7A CONV. 7B

CONV. 10

CONV. 12B U#2

S/R. MACH.

TRACK HOPER TP-1 PCH BUILDING SCH BUILDING U#1

SM-1 VF-1.2.3.4 VS-1.2.3.4 SM-2

PF-1&2 1A 2A PC-1.2.3.4 3A SC-1.2.3.4 4A 4A 5A 6A

PF-3&4 1B 2B BF-1.2.3.4 3B BF-5.6.7.8 4B 4B 5B 6B

SM-3

TP-3 TP-4 TP-5 TP-6 54 METER

Coal Crushers:-

We receive the coal in the form of odd shaped lumps. These lumps are to

be crushed to required size. These lumps are crushed by coal crushers. 

crusher are of two type :-

1. PRIMARY CRUSHER:- Raw coal from track hopper comes to

primary crushing house via conveyor belt after crushing in primary

crusher size of coal becomes 150 mm. This coal of 150 mm is send to

secondary crusher through conveyor belt.

2. SECONDARY CRUSHER:-

Crushed coal of 150 mm is goes to secondary crusher after being

crushed is coal becomes 20mm. After coal crushed twice it send for

further power operation.

Trippers:-

These are the motorized operated machines and are used for feeding the

coal to coal bunkers as per their requirement.

Electromagnetic Separators:-

Electromagnets are used for removing of Iron and magnetic impurities

Page 15: COAL HANDLING DIVISION ANPARA

from the coal.

Dust Extraction System:-

This system is provided in CHP for suppression of coal dust in coal

handling plant. 

Operational Cycles:-

1. Normal Bunkering cycle.

2. Stacking cycle.

3. Reclaiming Cycle.

Normal Bunkering Cycle:-

Shifting of coal received from coal wagons directly to coal bunkers is

normal bunkering cycle.

Stacking Cycle:-

When there is no coal requirement at coal bunkers even then CHP has to

unload the received coal which is stacked at open ground called yard.

This is stacking cycle. 

Reclaiming Cycle:-

when coal wagons are not available the requirement of coal bunkers is

fulfilled from the stacked coal this is reclaiming cycle.

Precautionary Measures before Transporting Coal

Weighing of Coal:-

Weighing of coal is carried out at wagon tippler. Weight of loaded wagon

is taken; after unloading the coal, weight of empty wagon is taken the

difference of the two will give the weight of the coal (normally 55-60

metric ton of coal come in each wagon).

Payment of Coal:-

Payment of coal is made to the coalmines as per the weighing of coal

carried out at their premises. However, if any dispute arises regarding

Page 16: COAL HANDLING DIVISION ANPARA

weighing of coal same is to be settled by the committee of both the

parties. 

Stone shells:-

Sometimes stone shells are received along with coal same has to be

removed from the coal before bunkering and is done sometimes manually

or by different type of machines.

If quantum of stone shells is beyond minimum limit the cost of the coal is

recovered from the coal mines against the quantity of stone shells

received from them.

Chemical Analysis of Coal:-

Sample of coal is randomly collected from each rake by concerned

division staff 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 Problems faced in Coal Handling Plant:-

1. Design Problems:-Coal received in power station is having cal. Value much

less and ash percentage more than the rated values recommended by

manufacturer. Hence the systems in coal handling plant get overloaded resulting

in low bunkering.

2. Rainy Season Problems:-Chute choke ups, Coal yard -Slurry Formation

Transfer chutes gets choked up due to wet or muddy coal. Slurry formed in coal

yard may cause problems with electro-magnetic feeders at input points, frequent

choke-ups at transfer chutes etc.

3. Other Misc. Problems:-Snapping of belts get damaged or broken because of

jerks and overloading problems due to various reasons. Repairing and

replacement of these belts and ropes require more time for maintenance.

Page 17: COAL HANDLING DIVISION ANPARA

• Derailment of coal wagons:-De-ailment of wagons result in obstacle in

unloading of balance wagons in line. This results in lower bunkering and may

attract demurrage charges from railway department.

• Oversized coal/Muddy Coal:-Oversized / muddy coal may cause damage to

the belt system, frequent choke-ups of transfer chutes and damages to the

crusher rings.

DU ST M AN A G E M E N T A T C O A L H AND LI N G P L AN T O F T.P.P .

INTRODUCTION:-

Coal fire thermal power plant sere keys to power production in the country.

They play vital role in power generation and distribution, and constitute

64.75%oftotalpower production in India. Since coal is the basic raw material

used in such power plant, so they are equipped with a large coal handling plant

(CHP) where coal transported from coal mines are stored and processed before

sending to boiler and steam generation section. A CHP may also be called

a"coal handling and preparation plant"(CHPP).At this plant, major ergonomic

concern is of dust particles which become air borne while coal storage and

processing. CHP require very large area for coal storage and processing,

therefore large scale dust generation occurs at such plant. People working here

become victim of Pneumoconiosis which is an occupational lung disease and

are attractive lung disease caused by the inhalation of dust. Thus ergonomic

design of CHP is necessary for betterment of workers and authority concern.

Since CHP require large amount of water for dust suppression, therefore

innovative methods have to be design in order to minimize use of water. Since

many thermal power plant in India facing acute shortage of water, therefore

efficient method of dust suppression and prevention is highly recommended

Page 18: COAL HANDLING DIVISION ANPARA

which uses least amount of water. The following paper discusses design of a

dust collector which discharges dust in concentrated form in order to reduce

water consumption. A part from Dust Collector, typical nozzle design is also

proposed which utilizes elegant diverging water spray for dust prevention

minimizing water wastage. Dust suppression plays vital role in improving

performance of workers and their health, hence ergonomic design of CHP is

very important issue discussed at industry level, especially at Thermal Power

Plant.

Layout of a Typical Coal Fired Thermal Power Plant

The above diagram typically outline a coal fire thermal power plant where coal

transported from coal mines through coal vessels called wagon Tripler is

unloaded and coal silo is formed. As clearly outline the major region of dust

generation while performing above operations results in large scale airborne

particles which must be suppressed. We clearly define the region for which

ergonomic design should be proposed. The dust particles emanating from coal

are typically is of size 1 to 100 microns. A typical NTPC plant requires 4.4

cubic meters per megawatt per hour.

DESIGN PROPOSALS FOR DUST CONTROL AT FIVE DIFFERENT

STAGES OF A TYPICAL CHP OF A THERMAL POWER PLANT:-

Page 19: COAL HANDLING DIVISION ANPARA

Design proposals for preventing and suppressing dust at CHP using efficient

methods. The above figure clearly depicts the design proposal for preventing

and suppressing dust at CHP using efficient methods and implementing cutting

edge technology. The given design proposal targets five different stages where

dust generation is quite large.

STAGE1

At this stage, coal transported from coal mines is brought at CHP using Wagon

Tripler and unloaded to reclaimer. Large amount of dust is generated and in

order to prevent dust, moisture addition is most efficient techniques water is

very powerful binding solvent. Directly adding moisture to coal prevents dust

from becoming air borne. Here diverging nozzles are used for moisture

addition. Diverging nozzle will allow optimum proportionate of water to be

added with coal. Since it is necessary to know exactly what amount of water to

be added as too much water will cause mud and make coal heavier, on the other

hand, too little water will be in effective in dust control.

STAGE2

Here (reclaimer stage) coal is unloaded from wagon Tripler to be reclaimed.

The area where reclaiming is done is quite large and hence water addition will

Page 20: COAL HANDLING DIVISION ANPARA

be futile. Also wind play devastating role in increasing dust. Thus wind is the

major factor .So wind speed i s c o n t r o l l e d in order to prevent dust to

become air borne. Wind shield net or wind break forest is provided in order to

reduce dust generation.

STAGE3

Reclaimer piles up the coal at a largest or age area and form as stacker or coal

pile. While doing this, large amount of dust is generated. Also coal stacker is a

constant source of airborne dust particles. Therefore it is necessary to suppress

dust generation. At this stage surface compaction method is used to suppress

dust using 6-12% water solution of very good binding substance which binds

the coal dust and prevent it from becoming airborne. Moisture addition is done

at this stage using well designed spray which allow scone trolled flow of

solution over coal pile in order to properly suppress dust without affecting the

quality of coal.

STAGE4

This stage is major area of concern because dust particle size is a slow as1-

10microns.Therefore this stage requires a suitable, innovative and efficient

technique of dust suppression. Since moisture addition is futile exercise,

therefore we develop wet dust collector which can reduce dust concentration as

lowas1%in the concerned area. Dust collector is very elegant device which

discharges dust in concentrated form reducing water consumption. Even for

suppressing1mmthick dust layer, we require large amount of water, but dust

collector with minimum use of water, suppresses large amount of dust. The

following section discusses design of wet centrifugal dust collector with

automatic discharge for suppressing dust at this stage. Here processed coal is

transferred from coal stack through convey or to relay section, hence large

amount of dust is generated which can be suppress seducing dust collector.

Page 21: COAL HANDLING DIVISION ANPARA

STAGE5

Last stage is unloading of coal from relay section and transfer to the boiler

section. At this stage, usual method of moisture addition is sufficient in cess

mall amount of dust generates which can easily be suppress using proper

amount of moisture addition. At this stage also, diverging nozzles of optimum

diameter are used for proper water spray.

D ES I G N O F A W E T C E N T R I F U G A L D U S T C O L L E C T O R :-

Centrifugal collectors use cyclonic action to separate dust particles from the

gas stream. In a typical cyclone, the dust gas stream enters at an angle and is

spun rapidly. The centrifugal force created by the circular flow throws the dust

particles toward the wall of the cyclone. After striking the wall, these particles

fall in to a hopper located underneath.

The most common types of centrifugal or inertial collectors in use today are:-

1) Single-cyclone separators

2) Cyclone Multiple-separators

3) Secondary Air Flow Separators

Page 22: COAL HANDLING DIVISION ANPARA

A typical wet centrifugal dust collector uses scrubbing effect of water to

suppress dust. Water is very good binding substance for dust and therefore it is

used as scrubbing element. This device applies the principle of film formation

over the dust layer and confines dust particles leaving fresh air to escape. The

power rating of motor varies as per requirement. This device uses the principle

of dynamic precipitation technique in which very high suction pressure suck the

dusty air and allow to centrifuge through it. Centrifugal action separates dust

from fresh air and fresh air is allowed to escape from to here from dust

collector.

The dust collector has a small tank full of water which has two valves. These

two springs loaded valves are operated to allow passage of concentrated dust

and automatic filling of fresh water using sensors. These sensors sense the

concentration level of dust in the container and when it goes beyond 90%,it

opens the discharge valve. This remains open until total discharge of

concentrated dust occurs from the tank. At the same time, it opens inlet valve

to allow fresh water to fill up.

The dust collector uses automatic discharge technique and hence save time

form annual operations for discharging and refilling. Also discharge is recycled

in order to have minimum water wastage. This centrifugal dust collector is very

efficient and requires minimum amount of water since it discharges dust in

concentrated form. Taking atypical case of a NTPC plant which uses 4.4cubic

meter per mega watt per hour, assuming power production of 1000MW, total

water consumption will be4400 million cubic meter water. This is huge amount

of water which is utilized at such plant. But with the above mentioned

techniques, if implemented properly can save large amount of water and hence

reduce chances of a cute water shortage.

R ES U L T SAND CONCLU S I O N :-

A wet centrifugal dust collector with automatic discharge can reduce airborne

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dust particle sand minimize water wastage. Al soother methods of dust

collection reduce dust and water was taigas discussed earlier. This has great

impact not only at workplace butyl so in environment. Proper implementation

of dust suppression and prevent in methods reduces health hazards of workers,

employees and people residing nearby. Since current situation demands eco-

friendly method soft dust suppression without much water wastage, above

mentioned ergonomic designs are noteworthy.

A REPORT OF THEVOCATIONAL TRAINING ON

“COAL HANDLING PLANT”

Page 24: COAL HANDLING DIVISION ANPARA

FOR THE PERIOD OF FOUR WEEKS FROM 15.06.15 TO 17.07.15

AT

ANPARA THERMAL POWER STATION ANPARA, SONEBHADRA U.P.

OF UPRVUNL

BY

RAJAT VERMA

B.tech (Elect.Engg) IIIrd Year

TO

SURYA PRAKASH PAL A. S. MISHRA

ASSISTANT ENGINEER EXCUTIVE ENGINEER

Page 25: COAL HANDLING DIVISION ANPARA

Turbine used in ATPS

Three phase synchronous generator (210MW) used at ATPS

Page 26: COAL HANDLING DIVISION ANPARA

: