04/07/2023

1

CONSTRUCTIONAND WORKING OFCOAL HANDLING PLANT

04/07/2023

2

PRESENTED BY

Shrikant S. Khating

04/07/2023

3

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

04/07/2023

4

INTRODUCTION

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.

04/07/2023

5

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

04/07/2023

6

TRANSPORTATION OF COAL5 ways of Transportation.

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

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

04/07/2023

7

BY RAIL WAY 80-90% 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.

04/07/2023

8

ANALYSIS OF COAL

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.

04/07/2023

9

GENERAL LAYOUT OF CHP

Wagon Tippler Crusher House

Bunkers

Tripper Trolley

Conv. Belts Vibrating Screens

Crushers

Feeder Surge Hopper

Hopper

04/07/2023

10

Operational Cycle

Wagon Tippler

Conveyer Belt System

Crushing Mechanism In CHP

CHP Auxiliaries

04/07/2023

11

OPERATIONAL CYCLE

Bunkering Cycle

Stacking Cycle

Reclaiming Cycle

04/07/2023

12

BUNKERING CYCLE

Bunkers

From W/T

Bunkering Belts

Surge Hopper

Vibrating Feeder

Crusher House

Crusher

04/07/2023

13

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

04/07/2023

14

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

04/07/2023

15

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.

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

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

04/07/2023

16

WAGON TIPPLER DRIVE SYSTEM

Motor

Pinion

Spur Gear

Thruster Brake

G / B

04/07/2023

17

Wagon tippler

Mesh of 250 mm * 250 mm

Hopper

Vibrating Feeder

Conveyor Belt

To crusher House

GENERAL LAYOUT OF W/T

04/07/2023

18

EQUIPMENT USED IN W/T

Water Sprinkler System. Dust Extraction System.

04/07/2023

19

CONVEYOR BELT SYSTEM

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

Interlocking Magnetic Separator

04/07/2023

20

CONSTRUCTION OF CONVEYOR BELT

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.

Net

Strength = 600 N

1000 mm

04/07/2023

21

CONVEYOR BELT DRIVE SYSTEM

Motor G / B

Fluid CouplingFilled with 3/4th oil

Fusible plug

Head End Pulley

Tail End Pulley

oSpeed before crusher 2.4 m/secoSpeed After Crusher 2.7 m/sec

Belt Speed

04/07/2023

22

COUNTER WEIGHT

Return Idlers

Idlers

Counter Weight

Head End Pulley

Tail End Pulley

Conveyor Belt

RailingTake-up Pulley

04/07/2023

23

IDLERS

Carry Side Return Side

Self Alignment Impact Return Roller Return Adjustment Roller

( Installed after every 25m )

Below Discharge chute( rubber coating )

35°

04/07/2023

24

ANGLE OF IDLERS

Angle Merits Demerits

20° No middle idler is overloaded

More Coal Derailed

35° Coal not Derail. Middle idler is overloaded

04/07/2023

25

PROTECTION SYSTEM

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.

04/07/2023

26

CRUSHING MECHANISM IN CHP

Three Stage Crushing System is used in Plant. 1.Double Roll Crusher 2.Rotary Breaker Crusher 3.Impact CrusherW / T No.4

DRCR RBCR Impact250 mm

80 mm

600 mm

20-25 mm

Stage 1 Stage 2

Stage 3

04/07/2023

27

DOUBLE ROLL CRUSHER ( DRCR )

Teeth

Roller

300 mm

04/07/2023

28

ROTARY BREAKER CRUSHER ( RBCR )

Striking Plate

Hole of diameter 100 mm

250 mm

80 mm

Stone shell

04/07/2023

29

IMPACT CRUSHER

Hammer

30 mm

Rotor

Coal

04/07/2023

30

Thank You.