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CONSTRUCTIONAND WORKING OFCOAL HANDLING PLANT

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

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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.

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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

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TRANSPORTATION OF COAL

5 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

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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.

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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.

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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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OPERATIONAL CYCLE

Bunkering Cycle

Stacking Cycle

Reclaiming 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/T

Crusher 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/T

Crusher House

Bunkering Belts

If Outer Supply of coal Is Not Present

Stacked Coal

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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

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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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EQUIPMENT USED IN W/T

Water Sprinkler System. Dust Extraction System.

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CONVEYOR BELT SYSTEM

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

Interlocking Magnetic Separator

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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

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CONVEYOR BELT DRIVE SYSTEM

Motor G / B

Fluid Coupling

Filled 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

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COUNTER WEIGHT

Return Idlers

Idlers

Counter Weight

Head End Pulley

Tail End Pulley

Conveyor Belt

Railing

Take-up Pulley

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IDLERS

Carry 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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ANGLE OF IDLERS

Angle Merits Demerits

20° No middle idler is overloaded

More Coal Derailed

35° Coal not Derail. Middle idler is overloaded

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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.

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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 Impact

250 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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Thank You.