This document provides information about boilers and co-generation plants. It discusses the major components of a boiler which include the coal handling plant, co-generation plant, ash handling plant, and boiler. It then describes what a boiler is, the process of steam generation, and that steam volume increases tremendously from water. It also discusses co-generation plants and how they simultaneously produce power and thermal energy from the same primary energy source.

1. BOILER & CO-GENERATION

2. MAJOR CONTITUENTS
DM PLANT
COAL HANDLIING
PLANT
CO-GENERATION
PLANT
ASH ANDLING
PLANT
BOIILER

3. INTRODUCTION TO BOILER
 ENCLOSED
PRESSURE VESSEL
 HEAT GENERATED BY
COMBUSTION OF
FUEL IS
TRANSFERRED TO
WATER TO BECOME
STEAM
 PROCESS:
EVAPORATION
 STEAM VOLUME
INCREASES TO 1,600
TIMES FROM WATER AND
PRODUCES TREMENDOUS
FORCE
 BOILER TO BE EXTREMELY
3
What is a boiler?

4. COGENERATION PLANT VIEW
20ATA
11ATA
3.9ATA
11ATA
3.9ATA
CONDENSER
CONDENSER
5 BAR TO PROCESS
M
~
20ATA
~~
~
H.P.HTR
35 MW
6 MW
31.4 MW
5.6 MW
54 ATA COMMON HEADER
43ATAHEADER
54 ATA COMMON HEADER
To Economiser
From BFP
B#4
150
TPH
Reynolds
Digestion 1, 3 & 4
B#3
140
TPH
B#2
80
TPH
B#1
80
TPH
~
Auxiliary Steam
4 BAR STEAM
6 MW
600/250
12 Bar
steam to
Dig-2
7BarHdr
7 BAR TO PROCESS
250 PSI
from Hi-
Tech

5. COGENERATI
ON
PLANT•CO-GENERATION MEANS SIMULTANEOUSLY PRODUCTION OF POWER
& USEFUL THERMAL ENERGY FOR PROCESS FROM THE SAME
PRIMARY ENERGY SOURCE. AS PER MINISTRY OF POWER CO-
GENERATION IS DEFINED AS ONE WHICH SIMULTANEOUSLY
PRODUCES TWO OR MORE FORMS OF USEFUL ENERGY SUCH AS
ELECTRIC POWER AND STEAM, ELECTRIC POWER & SHAFT
(MECHANICAL) POWER ETC... IT ALSO DEFINES ANY FACILITY THAT
USES WASTE INDUSTRIAL HEAT FOR POWER GENERATION BY
SUPPLEMENTING HEAT, NOT MORE THAN 50%, FROM ANY FOSSIL
FUEL.
• AT HINDALCO WE ARE HAVING THE COGENERATION PLANT IN
WHICH WE USE THE STEAM FOR THE PROCESS REQUIREMENT AS
WELL AS POWER GENERATION

6. WHAT IS A BOILER
 ANY CLOSED VESSEL EXCEEDING 22.75
LITRES IN CAPACITY WHICH IS USED
EXCLUSIVELY FOR GENERATING STEAM
UNDER PRESSURE INCLUDES ANY
MOUNTING AND OTHER FITTING
ATTACHED TO SUCH VESSEL WHICH IS
FULLY OR PARTIALLY UNDER PRESSURE
WHEN SHUTOFF

7. AUXILIARIES OF BOILER
FANS
INDUCED
DRAFT
FAN
PRIMARY
AIR FAN
FORCED
DRAUGHT
FAN

8. ID FAN
• THE FUNCTION OF THIS FAN IS TO MAINTAIN THE DRAFT IN THE
FURNACE AND CARAY OUT FLUE GAS OF THE FURNACE AND MAINTAIN
THE NEGATIVE VALUE OF PRESSURE INSIDE THE FURNACE
PA FAN
• THE FUNCTION OF THIS FAN IS TO HEAT AND CARRY COAL FROM MILL
TO THE FURNACE ( PULVERISHED COAL).
FD FAN
• THE FAN IS USED FOR THE PURPOSE OF SUPPLYING EXCESS AIR IN
THE FURNACE FOR COMPLETE COMBUSTION OF COAL

9. AUXILIARIES OF BOILER
• The function of air preheater is to heat the incoming air
from the Primary air fan which is supplied to the mills,
Basically we are using this air as the medium for heating
and conveying the Pulverized coal. The air preheater is
located in the second pass of the Boiler and it gains its
heat by the flue gases and gives the heat to the incoming
air.
AIR
PREHEATER
• The Economizer is the located in the second pass of the
Boiler its function is to utilize the heat of flue gases
coming out of the first pass of the Boiler which have done
their work of producing steam from the Boiler. The
economizer utilizes this heat of Flue gases which would
otherwise be wasted to the atmosphere resulting in dry
flue gas loss and reducing the efficiency of the Boiler.
ECONOMISER

10. AUXILIARIES OF BOILER
• The function of the mill is to grind the coal in
the required size, like the size of coal required
in the Pulverized fuel fired Boilers is of 75
microns so to achieve that size the mills are
used. The mills used in the cogeneration plant
are of Ball mill and Bowl mill type.
MILL
• The function of super heater is to superheat
the Dry saturated steam coming from the drum
and convert it into the superheated from so
that chances of moisture is totally eliminated
and the Enthalpy of steam is increased.
SUPERHEATERS

11. AUXILIARIES OF BOILER
• The function of the Electrostatic
Precipitator is to collect the ash
coming out of the Boiler and
send it to the ash silo from
where it is further utilized as per
requirement. The ESP works on
the principle of Corona where
the Ash particles are charged
by Direct Current and further
collected at the collecting
electrodes and than removed
with the help of rappers and
collected in the ash silos.
ESP

12. DETAILS OF BOILERS
12
BOILERS TYPE CAPACITY
PR.
KG/CM2
TEMP.
0
C
YEAR OF
COMMISSI
ONING
MAKE
BOILER # 1
FRONT FIRING
(PF)
80 (TPH) 52.5 450 1986 WIL PUNE
BOILER # 2 AFBC 80 (TPH) 52.5 450 1989
BHEL,
TRICHI
BOILER # 3
TANGENTIAL
FIRING (PF)
140 (TPH) 111 535 1996
BHEL,
TRICHI
BOILER # 4
TANGENTIAL
FIRING (PF)
150 (TPH) 111 535 2004
BHEL,
TRICHI
STEAM GENERATION PER HOUR = 450 MT
STEAM RECEIVED FROM HI-TECH = 25-35 MT / HR

13. 13
DM
water
Deaerat
or
BFP
Coal to
feeder
s by
Dozer
Coal
Convey
ors
Rotory
Coal
Feeder
s
Furnace
Coal
Transport
ing Line
Steam
Generati
on
Flue
Gas
to
ESP
PA
Fa
n
FD
Fa
n
Econo
miser
Water Circuit
Coal
Yard
Coal sizing circuit
for
-6mm size coal
Coal
Bunkers
ID Fan
Ash Recycling
feeder-2 No.
Steam to Power Plant /
Process
Exchange
of Heat
Energy
Feeder
Running
YES
Ash
Hopper
NOAsh
drain
Ash Recycling
feeder-2 No.
Process Flow of Boiler#2

14. FLUIDISED BED COMBUSTION BOILER

15. AFBC BOILER
15
•AFBC – ATMOSPHERIC FLUIDIZED BED
COMBUSTION
•DEFINITION
WHEN AIR OR GAS IS PASSED THROUGH AN
INERT BED OF SOLID PARTICLE SUCH AS SAND
OR CRUSHED REFRACTORY, THE AIR STARTS
BUBBLING THROUGH THE BED AND PARTICLE
ATTAIN A STATE OF HIGH TURBULENCE.
UNDER SUCH CONDITIONS, THE BED ASSUMES
THE APPEARANCE OF A FLUID AND EXHIBITS
THE PROPERTIES ASSOCIATED WITH A FLUID AND

16. FBC MECHANISM
16
IF THE BED MATERIAL IN FLUIDIZED
STATE IS HEATED TO THE IGNITION
TEMPERATURE OF THE FUEL AND
THE FUEL IS INJECTED CONTINUOUSLY
INTO THE BED, THE FUEL WILL BURN
RAPIDLY AND BED ATTAINS A
UNIFORM TEMPERATURE DUE TO

17. AFBC BOILER - ADVANTAGE
17
• FLEXIBLE IN THEIR ABILITY TO BURN A WIDE RANGE OF FUEL.
• DOES NOT REQUIRE OIL SUPPORT FOR START UP OR LOW LOAD
STABILIZATION.
• BY ADDING OF LIMESTONE IN THE BED STRINGENT SOX EMISSION
CONTROL IS POSSIBLE WITHOUT EXPENSING DOWN STREAM SCRUBBER
EQUIPMENT
• AUXILIARY POWER CONSUMPTION IS LOW.
• BETTER LOAD RESPONSE AND CAN BE VARIED FROM 20% TO 100% OF
NCR.
• LESS INITIAL COST.
• EASY IN OPERATION.
• C & I REQUIREMENT FOR FBC ARE MINIMAL. NO BMS REQUIRED

18. AFBC BOILER - DISADVANTAGE
18
• SUITABLE FOR LOW AND MEDIUM CAPACITY ONLY.
• MORE MAINTENANCE COST DUE TO HIGH
EROSION OF TUBES.
• LOWER EFFICIENCY.
• MORE EFFORTS REQUIRED WHEN IT IS INITIALLY
START UP WITH CHARCOAL.

19. FUEL FEEDING SYSTEM
19
•Fuel is evenly distributed by judicious location of feed points for burning
most of the volatiles and carbon within the bed and to avoid localized fuel
concentration
Comp-1Comp-2Comp-3Comp-4
Coal feed points
Recycle ash feed
points
Distributor plates

20. AIR DISTRIBUTION
20
•PROPER AIR DISTRIBUTOR IS REQUIRED TO ENSURE UNIFORM
DISTRIBUTION OF AIR ACROSS BED CROSS SECTION
Comp-1Comp-2Comp-3Comp-4
Nozzles are provided across the bed for proper air distribution

21. BED TEMPERATURE & HEIGHT
21
•BED TEMPERATURE: - FBC NORMALLY
OPERATES AT A TEMPERATURE RANGE
750-950º C FOR COAL
• BED HEIGHT: - DETERMINED BY THE NEED TO
SUBMERGE HEAT EXCHANGER TUBES AND IN CASE OF
HIGH SULPHUR COAL THE VOLUME REQUIREMENT FOR
EFFECTIVE SULPHUR CAPTURE
FOR MOST OF THE INDIAN FUELS A SHALLOW BED LESS
THAN 1000 MM IS ADEQUATE.

22. BED TEMPERATURE & HEIGHT
22
Water
Heade
r
Air from FD Fan
Coal Transporting
Line
Primar
y Air
Bed material
in Fluidization
state

24. BLOCK DIAGRAM OF AFBC BOILER
24

25. TECHNICAL DATA
25
SN PARAMETER UNIT CAPACITY
1 Heating Surface M² 3426.9
2 Steam Flow TPH 80
3 Steam Pressure
Kg/Cm
²
52.5
4 Steam Temperature Deg C 450±5
5 Feed Water Temp. Deg C 105
6 Fluidized Air Temp Deg C 130
7 Boiler Efficiency % 82±1.5
Coal Size: -(-) 6 mm to Furnace with maximum 20% fines

26. 26
Boiler Flue gas
Steam Output
Efficiency = 100 – (1+2+3+4+5+6+7+8)
(by In Direct Method)
Air
Fuel Input, 100%
1. Dry Flue gas loss
2. H2 loss
3. Moisture in fuel
4. Moisture in air
5. CO loss
7. Fly ash loss
6. Surface loss
8. Bottom ash loss
WHAT ARE THE LOSSES THAT OCCUR
IN A BOILER?

27. 27
INTERMITTENT
BLOWDOWN
• THE INTERMITTENT BLOWN DOWN IS GIVEN
BY MANUALLY OPERATING A VALVE FITTED
TO DISCHARGE PIPE AT THE LOWEST POINT
OF BOILER SHELL TO REDUCE PARAMETERS
(TDS OR CONDUCTIVITY, PH, SILICA ETC)
WITHIN PRESCRIBED LIMITS SO THAT
STEAM QUALITY IS NOT LIKELY TO BE
AFFECTED
• TDS LEVEL KEEPS VARYING
• FLUCTUATIONS OF THE WATER LEVEL IN
THE BOILER.
• SUBSTANTIAL AMOUNT OF HEAT ENERGY IS

28. 28
•WHEN WATER EVAPORATES
•DISSOLVED SOLIDS GETS
CONCENTRATED
•SOLIDS PRECIPITATES
•COATING OF TUBES
•REDUCES THE HEAT TRANSFER
RATE
Why Boiler Blow Down ?

29. PULVERIZED FIRE BOILER SKETCH

30. PULVERIZED FUEL BOILER
30
Tangential firing
Coal is pulverised to a fine powder, so that less than 2% is +300
microns, and 70-75% is below 75 microns.
Coal is blown with part of the combustion air into the boiler plant
through a series of burner nozzles.
• Combustion takes place at
temperatures from 1300-1700°C
• Particle residence time in the
boiler is typically 2-5 seconds
• One of the most popular system
for firing pulverized coal is the
tangential firing using four
burners corner to corner to
create a fire ball at the center of
the furnace.

31. ADVANTAGES
 ITS ABILITY TO BURN ALL RANKS OF COAL FROM
ANTHRACITIC TO LIGNITE, AND IT PERMITS
COMBINATION FIRING (I.E., CAN USE COAL, OIL
AND GAS IN SAME BURNER). BECAUSE OF
THESE ADVANTAGES, THERE IS WIDESPREAD
USE OF PULVERIZED COAL FURNACES.
DISADVANTAGES
 HIGH POWER DEMAND FOR PULVERIZING
 REQUIRES MORE MAINTENANCE, FLY ASH
EROSION AND POLLUTION COMPLICATE UNIT
OPERATION.
31
Pulverized Fuel Boiler

32. 32
PULVERIZED
FUEL
FIRING

33. FUELS SYSTEM IN PF BOILER#1
33
BALL MILL:-
• IT IS FRONT WALL FIRED PULVERIZED FUEL BOILER HAVING
FOUR BURNERS ON FRONT WALL.
• BOILER NO. 1 IS PULVERIZED FUEL BOILERS.
• OIL GUNS IS PROVIDED FOR START UP AND SUPPORT AT TWO
LEVELS.
• MINUS 20 MM SIZE COAL IS FED TO THE MILL THROUGH THE
TWO NUMBER VOLUMETRIC COAL FEEDERS.
AS THE MILL ROTATES, THE COAL IN THE MILL IS PULVERISED
BY THE CRUSHING AND GRINDING ACTION OF CASCADING
STEEL BALLS. PREHEATED AIR WHICH COMES FROM PRIMARY
AIR FAN, AND FUEL MIXTURE, AFTER PASSING THROUGH THE
CLASSIFIERS, ENTERS THE COAL CONDUITS AND PASSES ON

34. BALL MILL OF PF BOILER#1
34

35. FUELS SYSTEM IN PF BOILER#3 &
4
35
BOILER NO. 3 & 4 IS TANGENTIAL FIRED
PULVERIZED FUEL BOILER HAVING FOUR
ELEVATION BURNERS.
IN EACH ELEVATION FOUR COAL BURNER ARE
AVAILABLE.
FOUR NUMBER BOWL MILLS ARE THERE TO CRUSH
THE 20 MM SIZE COAL. OUT OF THESE FOUR MILLS,
THREE MILLS SHOULD BE IN SERVICE FOR FULL
STEAM LOAD.
BOWL AND ROLLERS ARRANGEMENTS ARE THERE
TO CRUSH THE 20-MM SIZE COAL INSIDE THE MILL.
HOT AIR FROM AIR PREHEATERS SUCKED BY THE

36. QUALITY OF COAL
36
Coal Feed Size
BOILER #1, 3 & 4: 100% (-) 20 MM TO MILL
70% (-) 200 MESH TO
FURNACE
BOILER#2 : (-) 6 MM WITH 20% FINES TO
MOISTURE
VOLATILE
MATTER
ASH
FIXED
CARBON
CALORIFIC
VALUE
10%-16% 21%-26% 35%-38% 25%-30%
2900-3500
KCAL/KG
Proximate Analysis
Values

37. 37
. REDUCE STACK TEMPERATURE
22O C REDUCTION IN FLUE GAS TEMPERATURE INCREASES BOILER
EFFICIENCY BY 1%
. COMBUSTION AIR PREHEATING
. FEED WATER PREHEATING USING
ECONOMIZER6OC RAISE IN FEED WATER TEMPERATURE, BY ECONOMISER/CONDENSATE
RECOVERY, CORRESPONDS TO A 1% SAVING IN FUEL CONSUMPTION
IN ORDER TO IMPROVE THERMAL EFFICIENCY BY 1%, THE COMBUSTION AIR
TEMP. MUST BE RAISED BY 20 DEG C.
ENERGY CONSERVATION
OPPORTUNITIES IN BOILER
. INCOMPLETE COMBUSTION

38. 38
Energy Conservation Opportunities in
Boiler
. CONTROL EXCESS AIR
For every 1% reduction in excess air ,0.6% rise in efficiency.
. RADIATION AND CONVECTION HEAT
LOSS
. AUTOMATIC BLOWDOWN CONTROL
. REDUCTION OF SCALING AND
SOOT LOSSES
. REDUCTION OF BOILER STEAM
PRESSURE

39. Performance of a Boiler
hg -the enthalpy of saturated steam in kcal/kg of steam
hf -the enthalpy of feed water in kcal/kg of water
Boiler Efficiency: Direct Method
Boiler efficiency () =
Heat output
Heat input
x 100 Q sx (hg – hf)
Q x GCV
x 100=
PARAMETERS TO BE MONITORED:
- QUANTITY OF STEAM GENERATED PER HOUR (QS) IN KG/HR
- QUANTITY OF FUEL USED PER HOUR (Q) IN KG/HR
- THE WORKING PRESSURE (IN KG/CM2(G)) AND SUPERHEAT
TEMPERATURE (OC), IF ANY
- THE TEMPERATURE OF FEED WATER (OC)
- TYPE OF FUEL AND GROSS CALORIFIC VALUE OF THE FUEL
(GCV) IN KCAL/KG OF FUEL

40. DM PLANT
 THE WATER TO BE FEED IN BOILER FOR STEAM
GENERATION MUST BE DEMINERALISED AS PER
SHOULD NOT CONTAIN ANY DISSOLVED SOLID
SUCH AS SILICA OR CHLORIDES AND CARBONATES
WHICH RESULTS IN SLUDEFE FORMATION AND
SCALE FORMATION IN THE BOILER RESULTING IN
LOW EFFICIENCY OF BOILER ,LOW RATE OF STEAM
GENERATION AND WASTAGE AND MORE
CONSUMPTION OF FUEL ACCOMPANING WITH
CORROSION OF INER BODY SURFACE OR CAN SAY
METAL OF BOILER BODY .
 SO FOR THIS PURPOSE WATER HAS TO BE
TREATED FIRST AND SHOULD MAINTAIN TDS(TOTAL
DISSOLVED SAOLID)AS LOW AS POSSIBLE BY
PROPER TREATMENT .

41. DM PLANT
PUMP
PUMP
AIR BLOWER
PUMP FLOW CHART OF D. M. PLANT
CW
TANK
DYNA-
-SAND
FILTE
R
M G F A C F S A C
DEGASSED
WATER
TANK
S B A
COLD DM
TANK
F W
TANK

42. DEMINERALIZATION OF WATER
• THE PROCESS OF DEMINERALIZATION RESULTS IN REMOVAL
OF MINERALS FROM WATER,.
CLEAR WATER IS RECEIVED FROM CLEAR WATER TANK AND THE
MONITORING OF PH (9.7-10.2) AND CONDUCTIVITY (BELOW 150
MICRO SIEMENS/CM) ON DAILY BASIS IS MADE.
DYNA SAND
FILTER
• SINGLE FILTER OF SAND SIZE 0.9 MM .ITS BASIC FUNCTION IS
TURBIDITY REMOVAL, INLET TURBIDITY TO THE FILTER IS 200PPM
AND OUTLET TURBIDITY IS LESS THAN 5 PPM ,ALUM DOSING IS
ALSO
DONE IN THIS FILTER.

43. MULTI GRATE FILTER
•THIS IS USED FOR THE REMOVAL OF TURBIDITY THE INLET
TURBIDITY
IS 40 PPM AND OUTLET TURBIDITY LESS THAN 5 PPM AT
PRESENT
WE ARE GETTING (0-1) NTU.
ACTIVATED
CARBON
FILTER•THIS IS USED TO ABSORB EXCESS CHLORINE, REMOVAL OF
ORGANIC MATTER AND OIL & GREASE IF ANY. AND CHARCOAL
IS
USED AS ACTIVATED CARBON IN THE ACTIVATED CARBON
FILTER.

44. STRONG ACID CATION
•THE STRONG ACID CATION RESIN EXCHANGES ALL CATION IN
WATER, THE CATION ASSOCIATED WITH ALKALINITY OR THOSE
COMBINED AS NEUTRAL SALTS ALL ARE REMOVED BY SAC RESIN.
I T HAS A GREATER AFFINITY FOR DIVALENT ION THAN THE
MONOVALENT ION AS A RESULT SELECTIVITY OF CA AND MG IS
MORE THAN FOR NA CONSEQUENTLY THE FRONT PORTIONS OF THE
RESIN BED ARE PREDOMINANT WITH CA & MG, WHILE NA GOES
TO THE TAIL SECTION OF THE RESIN BED AND SO THE NA ION SLIP
OUT OF CATION EXCHANGER DUE TO REGENERATIVE EFFECT OF
FREE
MINERAL ACID

45. DEGASSER
•IT IS USED FOR CARBON DIOXIDE REMOVAL . CARBONIC ACID
GENERATED IN SAC UNIT IS DECOMPOSED IN WATER+ CARBON
DIOXIDE AND IT ESCAPES OUT FROM THE TOP OF DEGASSER BY
DEGASSER BLOWER , MAXIMUM 6 PPM OF CO2 IS ALLOWED
AFTER DEGASSER UNIT.
STRONG BASE
ANION•SBA RESIN HAS GREATER AFFINITY FOR
IONIC SPECIES, SULFATE AND CHLORIDE THAN FOR THE MOLECULAR
CARBON DIOXIDE AND SILICA AND HIGHER SELECTIVITY FOR
SULFATE ION THAN CHLORIDE ION. AGAIN THERE IS DISTRIBUTION
OF CONTAMINANTS OVER THE RESIN BED WITH FRONT LAYER HIGH
IN SULFATE FOLLOWED BY CHLORIDE AND CARBON DIOXIDE AND
THE SILICA AT TAIL END OF THE BED.

46. MIXED BED
•THE MIXED BED DEMINERALIZATION PROCESS
CONSISTS OF SAC AND SBA RESIN INTIMATELY MIXED TO
BRING ABOUT THE DEMINERALIZATION OF WATER, IN EFFECT IT IS
MULTIPLE AND RANDOM TWO BED DEMINERALIZATION PAIRS
RESULTING IN VERY HIGH QUALITY OF DM WATER . HERE THE
LEAKAGE OF IONS CAUSED BY THE REGENERATING EFFECT OF
FMA OR OF NAOH FORMED IN THE EXCHANGING PROCESS IS
ABSENT ,THIS IS BECAUSE FMA GENERATED BY SAC RESIN IS
EXCHANGED BY NEIGHBORING SBA RESIN LIKE WISE NAOH
GENERATED BY SBA RESIN IS EXCHANGED BY ADJACENT SAC
RESIN .CATION RESIN IS HEAVIER THAN THE SBA RESIN SO
CATION FORMS THE DOWN LAYER . THE PARAMETERS AT THE
OUTPUT ARE PH-6 TO7,CONDUCTIVITY 2 MICRO SIEMENS/CM,
SILICA 0.02MG/LTR.

47. COAL
HANDLING
PLANT
coal yard
_
2
0
m
m
_
_
2
o
_
2
o
BOILER # 1 & 2 BUNKER FLOOR
Bunker
Boiler # 1
Bunker
Boiler # 2
Bunker
Boiler # 3
Tripper
Tripper Conveyor
BOILER # 3 BUNKER FLOOR
Tripper
Trolley
Tripper Conveyor
Conveyor No. 64
Reciprocating Feeder 1or 2
Reclain Conveyor
BC - 11831
To Old Circuit #1,#3 To Old Circuit # 2
Vibro Feeder Vibro Feeder
Impactor '+ / -' 6
mm'
Vibrating Screen
Impactor
-20mm Vibro Feeder
Vibrating Screen
'- 6 mm'
Coal
'+6 mm' Coal
'+20 mm' Coal
'BucketElevator
Daybin Conveyor
BC - 33830
Conveyor - 70
Conveyor - 69
Conveyor - 65
Cross Conveyor
NEW COAL CIRCUIT - FLOW CHART (COAL PLANT)
'- 20 mm' Coal

48. COAL PLANT OPERATION
•COAL IS UNLOADING FROM WAGON TIPPLER IN TWO SIZES I E: -
01. +25 MM AND –75 MM (ABOVE 25MM AND BELOW 75 MM)
02. –25 MM AND + 75MM (BELOW 25MM AND ABOVE 75MM)
• AFTER UNLOADING OF COAL WE FED THE DIFFERENT SIZE COAL
IN DIFFERENT BOILERS. WE HAVE FOUR BOILERS. THREE ARE PF
AND ONE IS FBC. IN PF BOILER WE HAVE USE THE COAL BELOW
THE 20MM. IN FBC BOILER WE HAVE USE THE COAL BELOW THE
6MM.FOR, WHICH VARIOUS EQUIPMENTS HAVE BEEN INSTALLED
IN COAL PLANT AREA.
•TO FEED THE COAL IN PF BOILERS (B#1,3 &4) PUSH THE COAL BY
DOZERS IN ROTORY FEEDERS GRIZZLY SITUATED IN COAL YARDS.
COAL IS COMING FROM RECLAIM CONVEYER TO CONVEYER#64,
THEN VIBRATING SCREEN HAVING SIZE OF 20MM THROUGH VIBRO
FEEDER. LESS THAT 20 MM COAL HAVE FALLEN THROUGH SCREEN
DIRECTLY TO CONVEYER#70 AND OVERSIZE COAL GOING TO
CONVEYER#70 THROUGH COAL IMPACTOR HAVING CAPACITY 120
TPH. FINALLY COAL IS GOING TO THE BUNKERS OF BOILER#1,3&4
THROUGH COMVEYER#70, DAYBIN CONVEYER AND TRIPPER

49. •TO FEED THE COAL IN FBC BOILER (B#2) PUSH THE COAL BY
DOZERS IN ROTARY FEEDERS GRIZZLY SITUATED IN COAL
YARDS. COAL IS COMING FROM RECLAIM CONVEYER TO
CONVEYER#64, VIBRO FEEDER THEN COAL IMPACTOR
(240TPH) TO TWO NUMBERS VIBRATING SCREENS HAVING
CAPACITY OF 120 TPH EACH THROUGH TWO VIBRO FEEDERS.
COAL HAS FALLEN THROUGH SCREEN DIRECTLY TO
CONVEYER#69(SIZE LESS THAT 6MM) AND OVERSIZE COAL
(ABOVE 6MM) GOING TO CONVEYER#64 THROUGH BUCKET
ELEVATOR HAVING CAPACITY 65 TPH FOR RECRUSHING IN
COAL IMPACTOR WITH FRESH COAL. CLOSE COAL CIRCUIT IS
RUNNING DURING COAL FEEDING IN B#2. FINALLY COAL IS
GOING TO THE BUNKERS THROUGH COMVEYER#70, DAYBIN
CONVEYER AND TRIPPER CONVEYER.

50. CHP
FLOW CHART
FLOW DIAGRAM FOR COAL HANDLING PLANT
Through Feeder Through Feeder
YES
Wagon Tippler (Crushed to less than 100 mm
size)
Newton In Motion Weighbridge for Weigment of wagons
C
a
o
o
m
C
o
e
e
s
S
z
e
L
e
s
s
h
a
n
5
0
0
m
m
100mm to 75mm and
less than 25mm size coal
collected in & out side the
coal shed for Boiler#1 &
3
75mm to 25mm size
coal collected in
side the coal shed
for Boiler#2
Reclaim Conveyor
Conveyor#64
Vibro Feeder (W)
For Boiler#1 & 3(51)
Vibro Feeder (E)
For Boiler#2(48)
Boiler#1 & 3 Coal
2
0
m
m
s
z
e
Boiler#2 Coal Impactor
(240 MT/HR)
8
m
m
s
z
e
B
U
C
K
E
T
E
L
E
V
A
B
u
n
k
e
r
s
o
Conv#
65
Vibro fdr#49 Vibro fdr#50

51. 51