This document provides an overview of a coal handling plant (CHP). It discusses the key components and processes within a CHP, including: - Transportation of coal primarily via railways to the plant. - Analysis of incoming coal to check quality matches agreements. - The general layout and flow of coal through the plant via wagon tipplers, conveyor belts, crushers, and bunkers. - The crushing process uses a three stage system to reduce coal size. - Operational cycles to bunker, stack, or reclaim coal depending on bunker levels and maintenance needs. - Key equipment used includes wagon tipplers, conveyor belts, double roll crushers, rotary break

1. CONSTRUCTIONAND WORKING OFCOAL HANDLING PLANT6/18/20101

2. PRESENTED BYShrikant S. Khating6/18/20102

3. indexIntroduction.

4. Availability of Coal in India.

5. Transportation of Coal.

6. Analysis of Coal.

7. General Layout of CHP.

8. CHP Auxiliary And Equipments6/18/20103

9. IntroductionWhat is CHP?CHP (C- Coal, H- Handling, P- Plant)

10. 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.

11. To Stack the coal to coal yard.6/18/20104

12. Availability of Coal In India.Mostly E and F grade coal used in India.Blending Is Done To get Average D Grade.6/18/20105

13. Transportation of Coal5 ways of Transportation.1. Railways.

14. 2. Ropeways.

15. 3. Roadways.

16. 4. waterways.

17. 5. Airway.6/18/20106Best and Cheap facility at DoorstepAvailable only for TPS nearer to coal minesFear of thiefwaterway may not be possible till TPS and Problem of recalling arises if coal dip in waterHave to build Runway near TPS which is very costly.

18. By Rail Way80-90% 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.6/18/20107

19. Analysis of CoalChemical 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.6/18/20108

20. General Layout Of CHP6/18/20109Wagon TipplerCrusher HouseHopperFeederSurge HopperConv. BeltsVibrating ScreensCrushersTripper TrolleyBunkers

21. 6/18/201010

22. Operational Cycle6/18/201011

23. Bunkering Cycle6/18/201012From W/TCrusher HouseSurge Hopper Vibrating FeederCrusherBunkering BeltsBunkers

24. Stacking Cycle6/18/201013From W/TCrusher HouseCoal Is not required if bunker is full or Due any maintenance By-Passed CoalStacking BeltsBunkering BeltsCrushed YardBunkers

25. Reclaiming Cycle6/18/201014If Outer Supply of coal Is Not PresentFrom W/TCrusher HouseNon-Crushed YardReclaiming BeltsStacked CoalBunkering BeltsCrushed YardBunkers

26. Wagon TipplerThese 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.6/18/201015Wt of the coal =Wt. of loaded wagon – Wt. of empty wagon

27. Wagon Tippler Drive System6/18/201016MotorThruster BrakeG / BPinionSpur Gear

28. General Layout Of W/tWagon tipplerHopperMesh of 250 mm * 250 mmVibrating FeederConveyor BeltTo crusher House6/18/201017

29. Equipment Used In W/TWater Sprinkler System.Dust Extraction System.6/18/201018

30. Conveyor Belt SystemConstruction of Conveyor BeltConveyor Belt Drive SystemCounter WeightIdlersProtection SystemInterlockingMagnetic Separator6/18/201019

31. Construction of Conveyor BeltSynthetic 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. 6/18/201020Strength = 600 N1000 mmNet

32. Conveyor Belt Drive System6/18/201021Fusible plugHead End PulleyMotorG / BFluid CouplingFilled with 3/4th oilTail End PulleyBelt SpeedSpeed before crusher 2.4 m/sec

33. Speed After Crusher 2.7 m/secCounter Weight6/18/201022IdlersConveyor BeltHead End PulleyTail End PulleyReturn IdlersTake-up PulleyRailingCounter Weight

34. Idlers6/18/201023Carry SideReturn SideSelf AlignmentImpactReturn RollerReturn Adjustment Roller( Installed after every 25m )Below Discharge chute( rubber coating )35°

35. Angle Of Idlers6/18/201024

36. Protection SystemInterlocking 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.6/18/201025

37. Crushing Mechanism In CHPThree Stage Crushing System is used in Plant.1.Double Roll Crusher2.Rotary Breaker Crusher 3.Impact Crusher6/18/201026W / T No.4600 mmImpactDRCRRBCRStage 380 mm250 mmStage 1Stage 220-25 mm

38. Double Roll Crusher ( DRCR )6/18/201027RollerTeeth300 mm

39. Rotary Breaker Crusher ( RBCR )6/18/201028250 mmStriking PlateHole of diameter 100 mmStone shell80 mm

40. Impact Crusher6/18/201029CoalHammer30 mmRotor

41. Thank You.6/18/201030