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 PLANT 6/18/2010 1

2. PRESENTED BY Shrikant S. Khating 6/18/2010 2

4. Availability of Coal in India.

5. Transportation of Coal.

6. Analysis of Coal.

7. General Layout of CHP.

8. CHP Auxiliary And Equipments6/18/2010 3

11. To Stack the coal to coal yard.6/18/2010 4

12. Availability of Coal In India. Mostly E and F grade coal used in India. Blending Is Done To get Average D Grade. 6/18/2010 5

14. 2. Ropeways.

15. 3. Roadways.

16. 4. waterways.

17. 5. Airway.6/18/2010 6 Best and Cheap facility at Doorstep Available only for TPS nearer to coal mines Fear of thief waterway may not be possible till TPS and Problem of recalling arises if coal dip in water Have to build Runway near TPS which is very costly.

18. 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. 6/18/2010 7

19. 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. 6/18/2010 8

20. General Layout Of CHP 6/18/2010 9 Wagon Tippler Crusher House Hopper Feeder Surge Hopper Conv. Belts Vibrating Screens Crushers Tripper Trolley Bunkers

21. 6/18/2010 10

22. Operational Cycle 6/18/2010 11

23. Bunkering Cycle 6/18/2010 12 From W/T Crusher House Surge Hopper Vibrating Feeder Crusher Bunkering Belts Bunkers

24. Stacking Cycle 6/18/2010 13 From W/T Crusher House Coal Is not required if bunker is full or Due any maintenance By-Passed Coal Stacking Belts Bunkering Belts Crushed Yard Bunkers

25. Reclaiming Cycle 6/18/2010 14 If Outer Supply of coal Is Not Present From W/T Crusher House Non-Crushed Yard Reclaiming Belts Stacked Coal Bunkering Belts Crushed Yard Bunkers

26. 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. 6/18/2010 15 Wt of the coal =Wt. of loaded wagon – Wt. of empty wagon

27. Wagon Tippler Drive System 6/18/2010 16 Motor Thruster Brake G / B Pinion Spur Gear

28. General Layout Of W/t Wagon tippler Hopper Mesh of 250 mm * 250 mm Vibrating Feeder Conveyor Belt To crusher House 6/18/2010 17

29. Equipment Used In W/T Water Sprinkler System. Dust Extraction System. 6/18/2010 18

30. Conveyor Belt System Construction of Conveyor Belt Conveyor Belt Drive System Counter Weight Idlers Protection System Interlocking Magnetic Separator 6/18/2010 19

31. 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. 6/18/2010 20 Strength = 600 N 1000 mm Net

34. Idlers 6/18/2010 23 Carry Side Return Side Self Alignment Impact Return Roller Return Adjustment Roller ( Installed after every 25m ) Below Discharge chute ( rubber coating ) 35°

35. Angle Of Idlers 6/18/2010 24

36. 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. 6/18/2010 25

37. Crushing Mechanism In CHP Three Stage Crushing System is used in Plant. 1.Double Roll Crusher 2.Rotary Breaker Crusher 3.Impact Crusher 6/18/2010 26 W / T No.4 600 mm Impact DRCR RBCR Stage 3 80 mm 250 mm Stage 1 Stage 2 20-25 mm

38. Double Roll Crusher ( DRCR ) 6/18/2010 27 Roller Teeth 300 mm

39. Rotary Breaker Crusher ( RBCR ) 6/18/2010 28 250 mm Striking Plate Hole of diameter 100 mm Stone shell 80 mm

40. Impact Crusher 6/18/2010 29 Coal Hammer 30 mm Rotor

41. Thank You. 6/18/2010 30