The presentation contains the various types of coal fouund in India & the various ways of Handling of coal in palnt by various operations......

1. COAL HANDLING PLANT
PRESENTED BY
Vipul Sinha

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

3. What is coal…?
Coal is a type of fuel which is non renewable
in nature.
Cole is also known as BLACK DIAMOND.
It consist of high content of carbon.
It is the most impure form of carbon.
It is used for generation of heat by burning.
It is used in almost every thermal power plant
which is used to generate electricity.
It is used as a cooking fuel in many parts of
country.

4. 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.

5. 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

6. TRANSPORTATION OF COAL
5 ways of Transportation.
• 1. Railways.
• 2. Ropeways.
• 3. Roadways.
• 4. waterways.
• 5. Airway.

7. 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.

8. 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.

9. GENERAL LAYOUT OF CHP
Wagon Tippler Crusher House
Bunkers
Tripper Trolley
Conv. Belts Vibrating
Screens
Crushers
Feeder Surge
Hopper
Hopper

10. CHP Auxiliaries

11. OPERATIONAL CYCLE
Bunkering Cycle
Stacking Cycle
Reclaiming Cycle

12. BUNKERING CYCLE
Bunkers
From Wagon
Tippler
Bunkering
Belts
Surge
Hopper
Vibrating
Feeder
Crusher House
Crusher

13. STACKING CYCLE
Bunkers
Stacking Belts
Crushed
Yard
From Wagon Tippler
Crusher House
Bunkering
Belts
By-Passed Coal
Coal Is not required if
bunker is full or Due any
maintenance

14. RECLAIMING CYCLE
Bunkers
Reclaiming Belts
Crushed
Yard
Non-
Crushed
Yard
From Wagon Tippler
Crusher House
Bunkering
Belts
If Outer Supply of
coal Is Not Present
Stacked Coal

15. 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

16. WAGON TIPPLER DRIVE SYSTEM
Motor
Pinion
Spur
Gear
Thruster Brake
G / B

17. Wagon tippler
Mesh of 250 mm * 250 mm
Hopper
Vibrating Feeder
Conveyor Belt
To crusher
House
GENERAL LAYOUT OF W/T

18. EQUIPMENT USED IN W/T
• Water Sprinkler System.
• Dust Extraction System.

19. CONVEYOR BELT SYSTEM
• Construction of Conveyor Belt
• Conveyor Belt Drive System
• Counter Weight
• Idlers
• Protection System
• Interlocking
• Magnetic Separator

20. 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

21. 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/sec
oSpeed After Crusher 2.7 m/sec
Belt Speed

22. COUNTER WEIGHT
Return Idlers
Idlers
Counter Weight
Head End
Pulley
Tail End Pulley
Conveyor
Belt
Railing
Take-up Pulley

23. IDLERS
Carry Side Return Side
Self Alignment Impact Return Roller Return Adjustment
Roller
( Installed after
every 25m )
Below Discharge
chute
( rubber coating
)
35°

24. 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.

25. CRUSHING MECHANISM IN CHP
• Three Stage Crushing System is used in Plant.
• 1.Double Roll Crusher
• 2.Rotary Breaker Crusher
• 3.Impact Crusher
W / T No.4
DRCR RBCR Impact
250 mm 80 mm
600 mm
20-25 mm
Stage 1 Stage 2
Stage 3

26. DOUBLE ROLL CRUSHER ( DRCR )
Teeth
Roller
300 mm

27. ROTARY BREAKER CRUSHER ( RBCR )
Striking Plate
Hole of diameter 100
mm
250 mm
80 mm
Stone
shell

28. IMPACT CRUSHER
Hammer
30
mm
Rotor
Coal