Coal Handling Plant ( CHP )


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Coal Handling Plant ( CHP )

  2. 2. PRESENTED BY<br />Shrikant S. Khating<br />6/18/2010<br />2<br />
  3. 3. index<br /><ul><li>Introduction.
  4. 4. Availability of Coal in India.
  5. 5. Transportation of Coal.
  6. 6. Analysis of Coal.
  7. 7. General Layout of CHP.
  8. 8. CHP Auxiliary And Equipments</li></ul>6/18/2010<br />3<br />
  9. 9. Introduction<br />What is CHP?<br /><ul><li>CHP (C- Coal, H- Handling, P- Plant)
  10. 10. Which properly handles the coal from its receipt to transferring it to bunkers. </li></ul>Objective of CHP :-<br /><ul><li>To supply the quanta of processed coal to bunkers of Coal mills for Boiler operation.
  11. 11. To Stack the coal to coal yard.</li></ul>6/18/2010<br />4<br />
  12. 12. Availability of Coal In India.<br />Mostly E and F grade coal used in India.<br />Blending Is Done To get Average D Grade.<br />6/18/2010<br />5<br />
  13. 13. Transportation of Coal<br />5 ways of Transportation.<br /><ul><li>1. Railways.
  14. 14. 2. Ropeways.
  15. 15. 3. Roadways.
  16. 16. 4. waterways.
  17. 17. 5. Airway.</li></ul>6/18/2010<br />6<br />Best and Cheap facility at Doorstep<br />Available only for TPS nearer to coal mines<br />Fear of thief<br />waterway may not be possible till TPS and Problem of recalling arises if coal dip in water<br />Have to build Runway near TPS which is very costly.<br />
  18. 18. By Rail Way<br />80-90% of the requirement is fulfilled by this way.<br />Demurrage calculations on coal Rakes:- <br />We receive the coal wagons in the form of rakes <br /> (55-60 wagons in each rake).<br />Free time normally 7 hrs. from Receipt of coal. <br />Free time is calculated from the receipt of written intimation of coal rakes from MAHAGENCO to the railway.<br />Rate of demurrage is Rs.100 / wagon / hr.<br />6/18/2010<br />7<br />
  19. 19. Analysis of Coal<br />Chemical Analysis of Coal:-<br /> 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.<br />6/18/2010<br />8<br />
  20. 20. General Layout Of CHP<br />6/18/2010<br />9<br />Wagon Tippler<br />Crusher House<br />Hopper<br />Feeder<br />Surge Hopper<br />Conv. Belts<br />Vibrating Screens<br />Crushers<br />Tripper Trolley<br />Bunkers<br />
  21. 21. 6/18/2010<br />10<br />
  22. 22. Operational Cycle<br />6/18/2010<br />11<br />
  23. 23. Bunkering Cycle<br />6/18/2010<br />12<br />From W/T<br />Crusher House<br />Surge Hopper <br />Vibrating Feeder<br />Crusher<br />Bunkering Belts<br />Bunkers<br />
  24. 24. Stacking Cycle<br />6/18/2010<br />13<br />From W/T<br />Crusher House<br />Coal Is not required if bunker is full or Due any maintenance <br />By-Passed Coal<br />Stacking Belts<br />Bunkering Belts<br />Crushed Yard<br />Bunkers<br />
  25. 25. Reclaiming Cycle<br />6/18/2010<br />14<br />If Outer Supply of coal Is Not Present<br />From W/T<br />Crusher House<br />Non-Crushed Yard<br />Reclaiming Belts<br />Stacked Coal<br />Bunkering Belts<br />Crushed Yard<br />Bunkers<br />
  26. 26. Wagon Tippler<br />These are used to unload the coal wagons into coal hoppers in very less time (e.g. 20 wagons/hr. or more).<br />Weighing of coal is carried out at wagon tippler. <br />Normally 55-60 metric ton of coal come in each wagon.<br />6/18/2010<br />15<br />Wt of the coal =Wt. of loaded wagon – Wt. of empty wagon<br />
  27. 27. Wagon Tippler Drive System<br />6/18/2010<br />16<br />Motor<br />Thruster Brake<br />G / B<br />Pinion<br />Spur Gear<br />
  28. 28. General Layout Of W/t<br />Wagon tippler<br />Hopper<br />Mesh of 250 mm * 250 mm<br />Vibrating Feeder<br />Conveyor Belt<br />To crusher House<br />6/18/2010<br />17<br />
  29. 29. Equipment Used In W/T<br />Water Sprinkler System.<br />Dust Extraction System.<br />6/18/2010<br />18<br />
  30. 30. Conveyor Belt System<br />Construction of Conveyor Belt<br />Conveyor Belt Drive System<br />Counter Weight<br />Idlers<br />Protection System<br />Interlocking<br />Magnetic Separator<br />6/18/2010<br />19<br />
  31. 31. Construction of Conveyor Belt<br />Synthetic rubber.<br />4 ply means 4 nylon net in between 2 mm thick rubber coating is used.<br />At KTPS belt of 1000 mm width is used.<br />Width varies from 500 mm -1400 mm. <br />6/18/2010<br />20<br />Strength = 600 N<br />1000 mm<br />Net<br />
  32. 32. Conveyor Belt Drive System<br />6/18/2010<br />21<br />Fusible plug<br />Head End Pulley<br />Motor<br />G / B<br />Fluid Coupling<br />Filled with 3/4th oil<br />Tail End Pulley<br />Belt Speed<br /><ul><li>Speed before crusher 2.4 m/sec
  33. 33. Speed After Crusher 2.7 m/sec</li></li></ul><li>Counter Weight<br />6/18/2010<br />22<br />Idlers<br />Conveyor Belt<br />Head End Pulley<br />Tail End Pulley<br />Return Idlers<br />Take-up Pulley<br />Railing<br />Counter Weight<br />
  34. 34. Idlers<br />6/18/2010<br />23<br />Carry Side<br />Return Side<br />Self Alignment<br />Impact<br />Return Roller<br />Return Adjustment Roller<br />( Installed after every 25m )<br />Below Discharge chute<br />( rubber coating )<br />35°<br />
  35. 35. Angle Of Idlers<br />6/18/2010<br />24<br />
  36. 36. Protection System<br />Interlocking is used for safety purpose.<br />If any belt fails all other belts stop working which are interconnected.<br />Magnetic Separator is used to remove metal particle from coal conveyed through conveyor belt for improving boiler efficiency.<br />6/18/2010<br />25<br />
  37. 37. Crushing Mechanism In CHP<br />Three Stage Crushing System is used in Plant.<br />1.Double Roll Crusher<br />2.Rotary Breaker Crusher <br />3.Impact Crusher<br />6/18/2010<br />26<br />W / T No.4<br />600 mm<br />Impact<br />DRCR<br />RBCR<br />Stage 3<br />80 mm<br />250 mm<br />Stage 1<br />Stage 2<br />20-25 mm<br />
  38. 38. Double Roll Crusher ( DRCR )<br />6/18/2010<br />27<br />Roller<br />Teeth<br />300 mm<br />
  39. 39. Rotary Breaker Crusher ( RBCR )<br />6/18/2010<br />28<br />250 mm<br />Striking Plate<br />Hole of diameter 100 mm<br />Stone shell<br />80 mm<br />
  40. 40. Impact Crusher<br />6/18/2010<br />29<br />Coal<br />Hammer<br />30 mm<br />Rotor<br />
  41. 41. Thank You.<br />6/18/2010<br />30<br />