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Presented By-Pulak Pattanaik

8th SemesterMechanical Engineering

CONSTRUCTIONAND WORKING OF

COAL HANDLING PLANT

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About coal. Introduction.Availability of Coal in India.Transportation of Coal.Analysis of Coal.General Layout of CHP.CHP Auxiliary And Equipment'sMaintenance of CHP.References.

CONTENTS

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Coal is a type of fuel which is nonrenewable in nature.

Coal is also known as black diamond. It consists of high content of carbon. It is the most impure form of carbon. It is used for generation of heat by burning. It is used as cooking fuel in most part of

country.

WHAT IS COAL ?

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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.

Introduction

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

Grade.

Availability of Coal In India.

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

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5 ways of Transportation.

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

Transportation of Coal

Available only for TPS nearer to coal

mines

Have 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 water

Best and Cheap facility at Doorstep

Fear of thief

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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.

Analysis of Coal

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General Layout Of CHP

Wagon Tippler Crusher House

Bunkers

Tripper Trolley

Conv. Belts Vibrating Screens

Crushers

Feeder Surge Hopper

Hopper

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Operational Cycle

Wagon Tippler

Conveyer Belt System

Crushing Mechanism In CHP

CHP Auxiliaries

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Bunkering Cycle

Stacking Cycle

Reclaiming Cycle

Operational Cycle

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Bunkering Cycle

Bunkers

From W/T

Bunkering Belts

Surge Hopper

Vibrating Feeder

Crusher House

Crusher

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Stacking Cycle

Bunkers

Stacking Belts

Crushed Yard

From W/TCrusher House

Bunkering Belts

By-Passed Coal

Coal Is not required if bunker is full or Due

any maintenance

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Reclaiming Cycle

Bunkers

Reclaiming Belts

Crushed Yard

Non-Crushed Yard

From W/TCrusher House

Bunkering Belts

If Outer Supply of coal Is Not Present

Stacked Coal

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These are used to unload the coal wagons into coal hoppers in very less time (e.g. 20 wagons/hr. or more).

It is of two types Rota side tippler( rotate by 135deg) Rotary tippler(rotate by 180deg)

Weighing of coal is carried out at wagon tippler. It is rack and pinion type

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

Wagon Tippler

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

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Wagon Tippler Drive System

Motor

Pinion

Spur Gear

Thruster Brake

G / B

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Wagon tippler

Mesh of 250 mm * 250 mm

Hopper

Vibrating Feeder

Conveyor Belt

To crusher House

General Layout Of W/t

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Water Sprinkler System. Dust Extraction System.

Equipment Used In W/T

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Construction of Conveyor Belt Conveyor Belt Drive System Idlers Protection System

◦ Interlocking◦ Magnetic Separator

Conveyor Belt System

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Synthetic rubber. It may be 4ply,5ply,6ply. 4 ply means 4 nylon net in between 2 mm thick rubber

coating is used. A belt of 1000 mm width is used. Width varies from 500 mm -1400 mm.

Construction of Conveyor Belt

Net

Strength = 600N

1000 mm

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Conveyor Belt Drive System

Motor G / B

Fluid CouplingFilled with 3/4th oil

Fusible plug

Head End Pulley

Tail End PulleyoSpeed before crusher 2.4 m/secoSpeed After Crusher 2.7 m/sec

Belt Speed

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IDLERSCarry Side Return Side

Self Alignment Impact Return Roller Return Adjustment Roller

( Installed after every 25m )

Below Discharge chute( rubber coating )

35°

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Vibrating feeder-the coal stored in a huge hub is collected on the belt through vibrations created by vibrating feeders.

Flap gates-these are used to channelize the movement of coal.

Metal detector-these detect the presence of any ferrous and non ferrous metal in the coal.it consists of transmitter and receiver.

Reclaim hopper-process of taking coal from the dead storage for preparation and feeding to reclaim hoppers.

EQUIPMENT USED IN COAL HANDLING PLANT

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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.

Protection System

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Three Stage Crushing System is used in Plant.◦ 1.Double Roll Crusher◦ 2.Rotary Breaker Crusher◦ 3.Impact Crusher

Crushing Mechanism In CHP

W / T No.4

DRCR RBCR Impact250 mm

80 mm

600 mm

20-25 mm

Stage 1 Stage 2

Stage 3

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Double Roll Crusher ( DRCR )

Teeth

Roller

300 mm

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Rotary Breaker Crusher ( RBCR )

Striking Plate

Hole of diameter 100 mm

250 mm

80 mm

Stone shell

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Impact Crusher

Hammer

30 mm

Rotor

Coal

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Fenglian Song,” Analysis of Optimization Configuration for Coal Handling System in Large Power Plant”, 2012, IEEE

  Technical paper on “Quality Assured Maintenance Management For Coal

Handling Plant” by Makarand Joshi, in M-News Edition 28 of Plant Maintenance Resource Center

  Technical paper on “Maintenance Method For Critical Equipment's Of Coal

Handling Plant” by Makarand Joshi, in M-News Edition 28 of Plant Maintenance Resource Center

International Journal of Advanced Engineering Technology E-ISSN 0976-3945

IJAET/Vol.II/ Issue IV/October-December, 2011/393-395 DUST MANAGEMENT AT COAL HANDLING PLANT OF ATHERMAL POWER PLANT

by Ankush Kumar, Sumit Chakraborty, Ankit Kumar , Saad Parvez & Dr. Marouf Wani 

Girja Lodhi, "Operation and Maintenance of Crusher House for Coal Handling in Thermal Power Plant," International Journal of Mechanical Engineering and Robotics Research, Vol. 2, No. 4, pp. 449-455, 

REFERENCES

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