COAL HANDLING PLANT

Coal Handling Plant

1. WORKING AND OPERATION OF COAL HANDLING PLANT GUIDED BY: PRESENTED BY: PROF. DR A.K. BEHERA BIBHUDATTA BISWAL PANKAJ KUMAR GROUP:5ME 1’B’

2. Contents Introduction Coal & It’s constituents General layout in CHP Equipment used in CHP Storage of coal Safety for coal handling plant

3. Introduction Fuel is the most essential requirement for any power generating station. In thermal power station coal is used as fuel. Coal is required in the power house to generate so that steam can be generated in power house. Coal inside the boiler should be completely in powder form so as to easily combustible. CHP (Coal handling plant) is a plant which handles the coal from its receipt to transporting it to boiler and store in bunker. It also processes the raw coal to make it suitable for boiler operation.

4. Coal & It’s Constituents Coal is a type of fuel which is non renewable in nature. It consists of high content of carbon. It is the most impure form of carbon. It is used for generation of heat by burning. 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. Carbon :-42.9% Hydrogen:-2.96% Nitrogen:-0.91% Sulphur:-0.33%

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

6. LAYOUT OF COAL HANDLING PLANT Wagon Tippler Crusher House Bunkers Tripper Trolley Conv. Belts Vibrating Screens Crushers Feeder Surge Hopper Hopper

7. Equipment Used In CHP Hopper Hopper is the first part use for feeding the coal to the belt conveyor. The main function of this part is to store the coal and feeding to the belt conveyor with constant discharge with help of wagons loading unloading mechanism. This wagon mechanism is installing bottom of the hopper which is to reduce the load on the belt conveyor because it’s keep the constant discharge.

8. Conveyer Belt A belt conveyor system consists of two or more pulleys, with an endless loop of carrying medium. One or both of the pulleys are powered, moving the belt and the material on the belt forward . Coal handling plant uses rubber to handle bulk materials including raw ore and aggregates. Synthetic rubber belt of 1000 mm width is used. Width varies from 500 mm -1400 mm.

9. Conveyer Belt Drive System

10. Vibrating Feeder The feeding process involves continuous and control coal flow to meet the requirement. Various type of feeders are used for this process. Feeders protect the belt conveyers from damage by feeding the material on to the belt conveyers from storage hoppers , at a controlled rate.

11. Crusher A crusher is a machine designed to reduce large Coal into smaller Coals, gravel, or rock dust . crushers are machines which use a metal surface to break or compress materials. A pulverize mill is used to pulverize coal for combustion in steam generating furnaces of power plants. Three Stage Crushing System is used in Plant. 1.Double Roll Crusher 2.Rotary Breaker Crusher 3.Impact Crusher

12. Bunkering Process The process involves feeding of bunkers and maintaining the level of bins. From the conveyer belt the coal is transferred into bunker or bin with the help of trippers. Motorised trippers are usually used where continuous a nd uniform distribution of coal along the conveyer is required or where frequent forward or reverse movement is required. Trippers having rigid welded steel frame to resist shock and minimize distortion.

13. Magnetic Separator Magnetic separation is a process in which magnetically susceptible material is extracted from a mixture using a magnetic force. This separation technique can be useful in mining iron as it is attracted to a magnet. There are more chances of ferrous metal pieces come along with coal from mine. It is essential to remove metal pieces to safe guard the crusher and belt conveyer from damage. Inline magnetic separators are provided ,for continuous and automatic extraction and discharge of tramp magnetic pieces from coal being discharged from conveyers as specified.

14. Storage of coal To store coal for a period of 30-90 days ,therefore the plant is not require to be shut down due to failure of coal supply. Storage of coal primarily a matter of production against coal strikes ,failure of transportation system & general coal shortages. Dead storage or outdoor storage In this storage the coal received at the power plant is stored in dead storage in the form of piles laid directly on the ground. the coal stored has the tendency to combine with oxygen of air and during this process coal loss some of its heating value and ignition quality. Due to oxidation the coal may ignite spontaneously .

15. Live storage or active storage Coal from a live coal storage pile is usually supplied to combustion equipment without the use of mobile equipment. The coal is usually stored in vertical cylinder bunkers or coal bins. Coal from bunkers is transferred to the boiler gate . Live coal storage bunkers are normally constructed with a diamond-shaped cross section storage area. The storage bunkers are made of steel or reinforced concrete to store the live coal.

16. Requirement of good coal handling plants at site It should have minimum maintenance. It should be simple It should be reliable It should supply coal continuously as per the demand of power plant. It should have minimum wear in running the equipment.

17. Safety for Coal Handling Plant Conventional methods in CHP for identifying the presence of damage are often visual methods. The damage may be cracks ,pitting , material degradation. The purpose of the inspection is to identify any degradation in t he integrity of the system during the service life and to provide an early warning in order that remedial action can be taken before failure occurs. Several type of NDT methods have to be implemented in coal handling plant.

18. References [1] Paper on “Operation and Maintenance of Coal Handling System in Thermal Power Plant” Lihua ZHAO, Yin LIN School of Mechanical Engineering, Northeast Dianli University, Jilin City, Jilin Province Changchun road 169,132012,China. [2] Paper on “Implementation of Quality Management System For Coal Handling Plant Of Thermal Power Station”. By: Makarand Joshi. [3] Reliability Measures Improvement and Sensitivity Analysis of a Coal Handling Unit for Thermal Power Plant [4] Devendra Kumar, R.K. Mandloi / International Journal of Engineering Research and Applications (IJERA) Vol. 3, Issue 1, January -February 2013, pp.581-587. [5] Operation and maintenance of crusher house for coal handling in thermal power plant. vol. 2, no. 4, October 2013.

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