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05/01/2023 1
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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