COAL HANDLING PLANT

4. WHY CHP IS NEEDED ?
TO TRANSPORT COAL RECEIVED
FROM MINES TO COAL BUNKER,
MAINTANING:
 CORRECT SIZE: (-) 200 mm
CRUSHED TO (-) 20 mm.
 CORRECT QUALITY –
COAL BLENDING (1:10)
 ADEQUATE QUANTITY

5. CHP CAPACITY
STAGE-II
 Capacity: 1500 MT/hr
 Designed Capacity: 1650 MT/hr
 Belt Speed: 3 m/s
 Belt width: 1400 mm
 Paddle Feeder capacity: 1125
MT/hr
 Crusher Capacity: 940 MT/hr.
 Total No.s of belt: 20
 Total belt length: 6.140 KM
 Total Bunker : 20
 Bunker Capacity: 1140 MT
 T/H Length- 200 m
 T/H Capacity: 3200 MT
STAGE-I
 Rated Capacity: 1250 MT/hr
 Designed Capacity: 1500 MT/Hr
 Belt Speed: 3 m/s
 Belt width: 1400 mm
 Paddle Feeder capacity: 750
MT/hr
 Crusher Capacity: 625 MT/hr.
 Total No.s of belt: 29
 Total belt length: 6.988 KM
 Total Bunker : 16
 Bunker Capacity: 800 MT
 T/H Length-200 m
 T/H Capacity: 2700 MT

6. CHP STOCK PILE
STAGE-I
 Stockyard:
14 days@ 306 MT/Hr For 14 days
= 102800 considering angle of
repose 38° .
Both side = 102800 X 2 = 25600
MT
Additional : 102800 MT.
Dead Stock: 12 % (Cannot be
reclaimed without mobile
equipment)
Stock Pile height 12 M
Emergence stock yard: 6000 MT
 S/R :
Peak Stacking-1500 MT/Hr.
Peak Reclaming:1250 MT/Hr.
STAGE-II
 Stockyard:
 Length of Stock Pile: 385 m
 Stock Pile height 10 M
 Stock Pile Width at base: 50 m
 Angle of repose 37° .
S/R :
Peak Stacking-1500 MT/Hr.
Peak Reclaming:1500 MT/Hr.

7. GRADE OF COAL GCV
‘A’ GRADE > 6280 kcal/kg
‘B’ GRADE 5601 - 6280
‘C’ GRADE 4941 - 5600
‘D’ GRADE 4201 - 4940
‘E’ GRADE 3361 - 4200
‘ F’ GRADE 2401 – 3360
‘G’ GRADE 1300 - 2400

8. COAL ANALYSIS
BLR DESIGNED FOR COAL QUALITY-
•Moisture : 20 %
•Ash : 34 %
•HGI : 55
•Volatile Material :22%
•Gross Calorific Value : 4000 Kcal/Kg.

9. PROXIMATE ANALYSIS
• Moisture : % 20 - 22 - 18 (22 – 17)
• Ash : % 34 – 40 - 24 (42 – 24)
•Volatile Matter: % 22 -18 -24 (18 – 24)
•Fixed Carbon :% 24 – 20 – 34(18 – 35)

10. ULTIMATE ANALYSIS
• Carbon % : 34 - 29 - 44 ( 27 – 45)
• Hydrogen % : 3 - 2.5 - 3.2 (24 - 3.3)
•Nitrogen % :0.92 -0.6 1.19 (0.58 - 1.2)
•Oxygen % : 6.9 -4.7 -8.59 (4 - 8.64)

11. CHP LAYOUT Stage-I

12. CHP STAGE-II LAYOUT

13. RIHAND CHP LAYOUT STAGE - III
46A
46B
37A37B
36A
47A
38A 39A
38B 39B
40A 40B
YARD
YARD
TRACK HOPPER
CR H
34A
34B
44
35A35B
45A 45B 33A33B
42A
42B
31A
32A
32B
43
31B
24A
TP 14
TP 15
TP 17
TP 16
PH 1
44
TP 9
TP 9ANX TP 20
TP21
TP19
TP 18
TP 27
PH 2
W T
TP 26
A B C D E F G H J A B C D EF G H J
UNIT-5 UNIT-6
P/P H -C
TP 23TP 22 TP 25TP 24
MD
SM
ILMS
ILMS
ILMS
MDBS
S.P
BS
P/P H -A
P/P H -B
MCC 3 D
MCC 3 B
MCC 3 A
MCC 3C
25A
MCC 3E
41B41A
36B

14. COAL CRUSHER
TRACK HOPPER CONVEYOR
DIRECT FEEDING TO BUNKER
COAL RECEIVED = COAL CONSUMPTTION
BUNKER CONVEYORS
COAL BUNKERS

15. TRACK HOPPER CONVEYOR
COAL CRUSHER
BUNKER CONVEYORS
REVERSABLE YARD CONVEYOR
R
EV. B
O
O
M
C
O
N
V.
STACKINGCON.
STACKING OPERATION
COAL RECEIVED > COAL CONSUMPTTIO

16. BUNKER CONVEYORS
COAL CRUSHER
TRACK HOPPER CONVEYOR
REVERSABLE YARD CONVEYOR
RECLAMING CONVEYOR
BUCKET
WHEEL
R
EV. B
O
O
M
C
O
N
V.
STACKINGCON.
RECLAIMING OPERATION
COAL RECEIVED <COAL CONSUMPTTION

17. WORKING OF PADDLE FEEDER

18. PROTECTION OF CONVEYOR
BELTS
Belt Sway
Switches
Pull
Chord
Switch
Pull
Chord
Under Speed / Slip
Monitor
Speed
Monitor
SAFETY DEVICES FOR BELT CONVEYORS

19. DRIVE MOTOR
FLUID COUPLING
BRAKE
GEAR BOX
COOLING
FAN
GEAR BOX
HOLD BACK UNIT
CONVEYOR BELT
CONVEYOR DRIVE SYSTEM

20. GENERAL ARRANGEMENT OF SINGLE DRIVE CONVEYOR SYSTEM
Drive
Pulley Snub
Pulley
LT
Bend
HT
Bend
Tail
Pulley
Take
Up
Pulley
Take Up
Weight
Return Idler
Toughing
Idler
IMPACT
IDLER
RECEIVING
CHUTESKIRT
BOARD

21. SCRAPER
Primary Scraper or Pre scraper : For removing the
heavy residue of materials adhering to the belt
surface, on return side of
the belt. These scraper is
made up of Polyurethane
blade & inclined against the
direction of belt travel.
Primary scraper are used :
Inherent moisture in the
lumpy material exceeds 15%.
Inherent moisture in fine size
material exceeds 12%.
Material is sticky in
characteristics.
When water is added to the
material externally.
SECONDARY
SCRAPER / MAIN
SCRAPER
Snub Pulley

22. ROLLER/IDLER ARRANGEMENT

26. HORIZENTAL
ASCENDING
HORIZENTAL ASCENDING

27. The pulley to be provided closely so as to increase the
warping angle of the driving pulley is called as snub pulley.
T1/T2 = eµθ
, Whereas θ= Angle of Contact, µ = coefficient
of friction between pulley & belt, T1= Tight side tension &
T2=slack side tension
θ = 180º
θ is More than 180º
SNUB PULLEY
T1
T2

28. TANDEM TYPE SINGLE DRIVE: ONE DRIVE SHAFT
TANDEM TYPE DRIVE: ONE SHAFT IS DIRECTLY DRIVEN &
OTHER SHAFT RECEIVES THE POWER THROUGH THE
GEAR OR CHAIN , THEREBY TWO SHAFTS ARE DRIVEN.

29. DUAL DRIVE
DUAL DRIVE

30. DUAL DRIVE : TWO SHAFTS ARE DRIVEN BY TWO SEPARATE MOTORS
MULTI DRIVE SYSTEM : MORE THAN TWO SHAFTS WERE DRIVEN BY
SEPARATE MOTORS.

31. MULTI DRIVE SYSTEM : MORE THAN TWO SHAFTS WERE DRIVEN BY
SEPARATE MOTORS.

32. VERTICAL GRAVITY TAKE UP SYSTEM

33. HORIZENTAL GRAVITY TAKE – UP SYSTEM

34. SCREW TAKE UP SYSTEM

35. PULLEYPULLEY
LAGGING SHEET

36. ON LINE
MAGNETIC
SEPERATOR

37. PLAIN HAMMER – 18 NO’S
TOOTHED HAMMER-20 NO’S
CRUSHING OF MATERIAL
BY COMBINATION OF
IMPACT & ROLLING
COMPRESSION.
BREAKER
PLATE
CAGE SCREEN PLATE
TRAMP IRON CHUTE
SUSPENSION BAR

38. TECHNICAL SPECIFICATION OF CRUSHER
(STAGE-I):
TYPE: RING GRANULATOR TK 16-54B
CAPACITY: 750 MTPH
MAX COAL INPUT: 400 mm 2%
LUMP SIZE: -250 mm 98%
PRODUCT SIZE: -20 mm 98%
FEED MATERIAL: COAL
MOISTURE CONTENT: 20% MAXIMUM
COAL HARD GROOVE INDEX: 50 TO 64
ROTOR SPEED : 600 RPM
MOTOR : 560 KW X 1440 RPM
FLUID COUPLING: XR-CDR-660 NU
(ELECON MAKE)
GEAR BOX: KAN 315/ S/ SO, RATIO 2.5:1
(ELECON MAKE)
FLEXIBLE COUPLING : FC 630 (ELECON
MAKE)
MATERIAL OF CONSTRUCTION:
ROTOR SHAFT: 818 M 40 BS:
4670-1971
SUSPENSION BAR : EN 24
SCREEN PLATE: AUSTENATIC
MAGANESE PLATE GRADE-111
IS:276.
CAGE & CRUSHER FRAME:
STRUCTURAL STEEL St-42 IS 226 /
152062
FRAME LINERS: TISCRAL C-45
ROTOR DISC FRAME- TISCRAL C-
45 / En-8 CK45
HAMMER RINGS: AUSTENATIC
MAGANESE STEEL
BREAKER PLATE: AUSTENATIC
MAGANESE STEEL

39. MAXIMUM SIZE OF MATERIAL & MINIMUM BELT WIDTH (mm):
Maximum diagonalMaximum diagonal
length of lumplength of lump
100100 150150 200200 250250 300300 400400 500500
Minimum belt widthMinimum belt width 400400 500500 600600 750750 900900 10501050 12001200
FORMULA FOR CALCULATTING CONVEYOR CAPACITY:
Q= 60 . A . . ν
Q: Conveying capacity in t/h.
A: Loaded cross sectional area of conveying material ( m3
).
: Bulk density of conveying material ( t/m3
).
Ν: Belt Speed (m/min)

40. POWER REQUIREMENT
ACCORDING TO JAPANESE INDUSTRIAL STANDARDS (JIS):
P=P1+P2+P3
= 0.06 . f . W. v. (L + L 0 )/367 + f. Qt . (L + L 0 )/367 ± h Qt/ 367 KW
P: POWER REQUIRED (KW)
P1: NO LOAD POWER(KW)
P2: HORIZENTAL LOAD POWER(KW)
P3: LIFTING LOAD POWER (Given with negative sign for descending belts)
(KW)
f : Coefficient of rotational friction of idlers.
w : Weight of moving parts other than the conveying material (Kg/m)
v : Belt speed (m/min)
L : Conveyor length (Horizontal centre distance between head & tail pulley) (m)
L 0 : Corrected value of centre distance (m)
: Bulk density of conveying material ( t/m3 )
Qt : Capacity (t/hr)
Qt: Qm . Whereas Qm: Conveying volume (m3
/ h)
h: Vertical height of ascending & descending lift including height of tripper, if
any (m)

41. P1: NO LOAD POWER(KW)
= 0.06 . f . W. v. (L + L 0 )/367
The required power is not proportional to conveyor length, because abrasion loss
of pulley, skirt rubber etc. & energy loss required for bending the belt exists without
relating to conveyor length, particularly because of which conveyor length of belt
plus compensated value is experimentally proportionate to the required power.
P1: HORIZENTAL LOAD POWER(KW)
= f. Qt . (L + L 0 )/367
P3: LIFTING LOAD POWER (Given with negative sign for
descending belts) (KW)
= ± h Qt/ 367 KW

43. LOADED CROSS SECTIONAL AREA

44. VALUE OF LOAD CROSS SECTIONAL AREA (A)

45. SURCHARGE ANGLE

53. Characteristics Min.
kg/cm2
Tensile Strength
Ibs/in2
Min. Elongation
%
Max.Abrasion Loss
mm3
General Light Duty
Service
> 150 > 2130 > 400 < 250
Medium Abrasion
Resistance
> 190 > 2700 > 450 < 200
High Abrasion
Resistance
> 240 > 3410 > 500 < 120
Super Abrasion
Resistance
> 180 > 2560 > 400 < 90
Oil Resistance > 140 > 1850 > 400 < 250
Moderate Oil
Resistance
> 155 > 2135 > 450 < 200
Heat Resistance
HRT1
> 180 > 2560 > 600 < 250
Heat Resistance
HRT2
> 150 > 2130 > 500 < 300
Heat Resistance
HRT3
> 170 > 2410 > 450 < 300
Flame Resistance FR
/ FRAS
> 140 > 1850 > 550 < 300
CHARACTERISTICS OF COVER RUBBER

54. Strength Class (KN/m) 3-PLY 4-PLY 5-PLY 6-PLY
500 500/3 500/4 500/5
630 630/3 630/4 630/5 630/6
800 800/3 800/4 800/5 800/6
1000 1000/3 1000/4 1000/5 1000/6
1250 1250/3 1250/4 1250/5 1250/6
1500 1500/4 1500/5 1500/6
1600 1600/4 1600/5 1600/6
1800 1800/5 1800/6
2000 2000/5 2000/6
2500 2500/6
3000 3000/6
STRENGTH CLASS / NUMBER OF PLY