This document provides an overview of coal handling plant equipment and operations across three stages. It describes the key equipment used such as conveyors, dust suppression systems, belt weighers, metal detectors, and crushers. Specific details are given about capacities, speeds, widths, lengths and numbers of equipment. Locations of some equipment are also mentioned. The control systems for equipment are described as moving from electro-mechanical to PLC to DDCMIS across the stages. Functions and parameters that can be controlled are also listed.

1. An Introduction

4. Box-N BOBR
Bottom Open Bottom Release

7. Wagon Tippler
WT Control Room
Dust Suppression System
Side Arm Charger
Coal Discharge Direction
Wagon Tippler

11. For removing tramp iron pieces
Location - discharge of Conv. 42A/B, 31A/B
Efficient cost-saving recovery of harmful
tramp iron in free-flowing materials
They are simple to install and have no
maintenance
Installed over conveyor .
.

12. To detect non-magnetic metallic materials present
Location - 32A/B head, 38 A/B

13. Removing left tramp iron pieces
Location - discharge of 32A/B in crusher – to remove any
tramp iron piece present in coal before
entering crusher
- TP 21 – to avoid entry of the same in bunker
- TP 27 – to eliminate the same from the coal coming
from stockyard
Installed at discharge of conveyors near pulley
ILMS includes belt, pulleys, magnet etc.

16. ROD GATES (2+2)
RACK AND PINION GATES (2+2)
VIBRATING SCREEN FEEDERS, (2+2) 940
TPH
RING GRANUATOS (CRUSHERS )
(2+2)940 TPH
BELT FEEDER (2+2)
REVERSIBLE BELT
FEEDERS (1+1)

19. 0m 800 MT
2m 730 MT
6.25 m
4m 650 MT
Capacity – 800 MT 6m 565 MT
Height - 26.3 m 8m 480 MT
Nos. – 9 x 2 10 m 395 MT
8.13 m
26.3 m
12 m 310 MT
14 m 225 MT
15 m 170 MT
16 m 140 MT
18 m 85 MT
20 m 45 MT
11.91 m
22 m 18 MT
26.3 m

24. Electro-Mechanical System Wear an tear of contacts because of heating
High cost of installation, maintenance and
Stage # 1
modification process
PLC Easy to modify and implement
( Programmable Logic Control )
Stage # 2
DDCMIS
The control system for all the coal handling
( Distributed Digital Control drives including conveyors, Dust Suppression
Monitoring and Information System, etc. shall be DDCMIS
System) Except for the Stacker Reclaimer and wagon
Stage # 3 tippler , which will be controlled by PLC

25. PLC focuses more on control
DDCMIS focuses more on Human Machine Interface

26. RESET
PCS/BSS/ ZSS
ACKNOWLEDGEMENT
NOTIFICATION
TABLE PCS/BSS/ZSS
STATUS
PUMP HOUSE
ALARM TABLE
VENTILATION
BELT WEIGHER
BYPASS
STATUS TABLE

28. EQUIPMENTS FUNCTIONS
Conveyors Auto /manual operation of gates/
Dust suppression system valves/ dampers, pumps, drives,
Paddle feeders Local / remote selection of
Mobile trippers over bunkers operation,
Belt weighers Status
indication, annunciation, interlo
Metal Detectors ck and protection of pumps/drives
Inline Magnetic separators
Suspended Magnets
Coal sampling Units
Hydraulic scoop Coupling

29. It consists of a series of overlapping Heavy Duty Pans (or Flights) that
carry the material.
Used for handling more abrasive, heavy and lumpy material. The
material is carried on an overlapping metal plate called pans, which is
mounted between strands of the conveyor chain.
Apron feeders are placed under storage bin for regulating the feed
material

31. An Apron Feeder can regulate the flow of material based on
volume. The pan speed and the gate cut off height can be regulated to
provide an even volumetric feed down stream.
.

32. A short belt conveyor. The belt is flat and supported on closely spaced
idlers or on a smooth slide plate.
Belt feeders are used for handling fine / free flowing / abrasive
materials. Even properly designed belt feeders are used for handling
lumpy material.
Increased redundancy and flexibility

33. Used when only one outlet is used to feed two different belts
2 in no. in stage 3
Location - Crusher house

34. Used when only one outlet is used to feed two different belts
2 in no. in stage 3
Location - Crusher house

35. More flexibility
More availability

36. Location – PH 1 head
Manual Stone Picking arrangement at conveyor gallery before the crusher
house shall be provided complete with stone picking accessories
Four (4) nos. manual pickers
Two (2) nos. manual pickers shall be positioned on each belt
Each manual picker shall cover 3 m long belt stretch
Disposal chute from discharge hoods of length up to 2 meters from ground
level
Conveyor Gallery shall be 2 meters wide

37. DESCRIPTION STAGE I STAGE II STAGE III
BELT CAPACITY 1250 MT 1500 MT 1500 MT
BELT SPEED 3.2 m/s 3.2 m/s 3.2 m/s
BELT WIDTH 1400 mm 1400 mm 1400 mm
TOTAL NO OF BELTs 29 20 40
TOTAL BELT LENGTH 6.98 Km 6.14 Km 16.93 km
TRACK HOPPER CAPACITY 2700 MT 3400 MT 4562.16 MT
WAGON TRIPPLER CAPACITY NA NA 194.33 MT
PADDLE FEEDER CAPACITY 625 TPH 1125 TPH 1125 TPH
CRUSHER CAPACITY 625 TPH 940 TPH 825 TPH
TOTAL NO OF BUNKERs 16 20 18
BUNKER CAPACITY 800 MT 1140 MT 800 MT
YARD CAPACITY ----- 192500 MT 182900 MT

38. Santosh Kumar Verma
CHP-OPN (Group D)