CONSTRUCTION
AND WORKING OF
COAL HANDLING
2/23/17
PLANT
1
2/23/17
PRESENTED BY
Shrikant S.
Khating
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INDEX
Introduction.
Availability of Coal in India.
2/23/17
Transportation of Coal.
Analysis of Coal.
General Layout of CHP.
CHP Auxiliary And Equipments
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INTRODUCTION
What is CHP?
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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.
2/23/17
Grade C.V. % Ash + Moisture
( K Cal / Kg. )
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
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F 2401-3360 40.14 - 47.10
TRANSPORTATION OF COALBest and Cheap
facility at Doorstep
5 ways of Transportation.
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Available only for TPS
1. Railways. nearer to coal mines
2. Ropeways.
3. Roadways.
4. waterways. Fear of thief
5. Airway.
waterway may not be possible
till TPS and Problem of
recalling arises if coal dip in
water
Have to build Runway near
TPS which is very costly. 6
BY RAIL WAY
80-90% of the requirement is fulfilled by this way.
2/23/17
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. 7
ANALYSIS OF COAL
Chemical Analysis of Coal:-
2/23/17
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
2/23/17
Wagon Tippler Crusher House
Hopper
Feeder Surge
Hopper
Conv. Belts Vibrating
Screens
Crushers
Tripper Trolley
Bunkers 9
Operational Cycle
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OPERATIONAL CYCLE
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Bunkering Cycle
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BUNKERING CYCLE
From W/T
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Crusher House
Surge Hopper
Vibrating Feeder
Crusher
Bunkering
Belts
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Bunkers
STACKING CYCLE
From W/T
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Crusher House
Coal Is not required if
bunker is full or Due any
maintenance
By-Passed Coal
Bunkering Stacking Belts
Belts
Crushed 13
Bunkers
Yard
RECLAIMING CYCLE
If Outer Supply of
coal Is Not Present
From W/T
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Crusher House
Non-
Crushed
Yard
Reclaiming Belts
Stacked Coal
Bunkering
Belts
Crushed
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Bunkers Yard
WAGON TIPPLER
These are used to unload the coal wagons into coal
hoppers in very less time (e.g. 20 wagons/hr. or more).
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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
2/23/17
Motor
Thruster
Brake
G/B
Pinion
Spur Gear 16
GENERAL LAYOUT OF W/T
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Wagon tippler
Hopper
Mesh of 250 mm * 250 mm
Vibrating Feeder
Conveyor Belt
17
To crusher
House
EQUIPMENT USED IN W/T
Water Sprinkler System.
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Dust Extraction System.
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CONVEYOR BELT SYSTEM
Construction of Conveyor Belt
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Conveyor Belt Drive System
Counter Weight
Idlers
Protection System
Interlocking
Magnetic Separator
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CONSTRUCTION OF CONVEYOR
BELT
Synthetic rubber.
2/23/17
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.
Strength = 600 N
1000 mm
Net
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CONVEYOR BELT DRIVE SYSTEM
Fusible Head End Pulley
2/23/17
plug
Motor G/B
Fluid Coupling
Filled with 3/4th oil
Tail End Pulley
Belt Speed 21
oSpeed before crusher 2.4 m/sec
oSpeed After Crusher 2.7 m/sec
COUNTER WEIGHT
Idlers Conveyor Belt
Head End Pulley
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Tail End Pulley
Return Idlers
Take-up Pulley
Railing
Counter Weight
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IDLERS
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Carry Side Return Side
Self Alignment Impact Return Roller Return Adjustment
Roller
( Installed after Below Discharge
every 25m ) chute
( rubber coating )
35 23
ANGLE OF IDLERS
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Angle Merits Demerits
20 No middle idler More Coal
is overloaded Derailed
35 Coal not Derail. Middle idler is
overloaded
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PROTECTION SYSTEM
Interlocking is used for safety purpose.
2/23/17
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.
2/23/17
[Link] Roll Crusher
[Link] Breaker Crusher
[Link] Crusher
W / T No.4
600 mm
Impact Stage 3
DRCR RBCR
250 mm 80 mm
Stage 1 Stage 2 26
20-25 mm
DOUBLE ROLL CRUSHER ( DRCR )
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Roller
Teeth
300 mm
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ROTARY BREAKER CRUSHER ( RBCR
)
2/23/17
250 mm
Striking
Plate
Hole of diameter 100
mm
Stone
shell
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80 mm
IMPACT CRUSHER
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Coal
Hammer
30 mm Rotor
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2/23/17
Thank You.
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