COAL HANDLING PLANT

CONSTRUTION AND ITS WORKING OF COAL HANDLING PLANT

1. 15-Aug-16 1 Presented By- Pulak Pattanaik 8 th Semester Mechanical Engineering CONSTRUCTION AND WORKING OF COAL HANDLING PLANT

2. About coal. Introduction. Availability of Coal in India. Transportation of Coal. Analysis of Coal. General Layout of CHP. CHP Auxiliary And Equipment's Maintenance of CHP. References. 15-Aug-16 2 CONTENTS

3. Coal is a type of fuel which is nonrenewable in nature. Coal is also known as black diamond. It consists 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 as cooking fuel in most part of country. 15-Aug-16 3 WHAT IS COAL ?

4. 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. 15-Aug-16 4 Introduction

5. Mostly E and F grade coal used in India. Blending Is Done To get Average D Grade. 15-Aug-16 5 Availability of Coal In India. 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. 5 ways of Transportation. 1. Railways. 2. Ropeways. 3. Roadways. 4. waterways. 5. Airway. 15-Aug-16 6 Transportation of Coal Available only for TPS nearer to coal mines Have to build Runway near TPS which is very costly. waterway may not be possible till TPS and Problem of recalling arises if coal dip in water Best and Cheap facility at Doorstep Fear of thief

7. 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. 15-Aug-16 7 Analysis of Coal

8. 15-Aug-16 8 General Layout Of CHP Wagon Tippler Crusher House Bunkers Tripper Trolley Conv. Belts Vibrating Screens Crushers Feeder Surge Hopper Hopper

9. 15-Aug-16 9

10. 15-Aug-16 10 Operational Cycle

11. 15-Aug-16 11 Bunkering Cycle Bunkers From W/T Bunkering Belts Surge Hopper Vibrating Feeder Crusher House Crusher

12. 15-Aug-16 12 Stacking Cycle Bunkers Stacking Belts Crushed Yard From W/T Crusher House Bunkering Belts By-Passed Coal Coal Is not required if bunker is full or Due any maintenance

13. 15-Aug-16 13 Reclaiming Cycle Bunkers Reclaiming Belts Crushed Yard Non-Crushed Yard From W/T Crusher House Bunkering Belts If Outer Supply of coal Is Not Present Stacked Coal

14. These are used to unload the coal wagons into coal hoppers in very less time (e.g. 20 wagons/hr. or more). It is of two types Rota side tippler( rotate by 135deg) Rotary tippler(rotate by 180deg) Weighing of coal is carried out at wagon tippler. It is rack and pinion type Normally 55-60 metric ton of coal come in each wagon. 15-Aug-16 14 Wagon Tippler Wt of the coal =Wt. of loaded wagon – Wt. of empty wagon

15. 15-Aug-16 15 Wagon Tippler Drive System Motor Pinion Spur Gear Thruster Brake G / B

16. Wagon tippler Mesh of 250 mm * 250 mm Hopper Vibrating Feeder Conveyor Belt To crusher House 15-Aug-16 16 General Layout Of W/t

17. Water Sprinkler System. Dust Extraction System. 15-Aug-16 17 Equipment Used In W/T

18. Construction of Conveyor Belt Conveyor Belt Drive System Idlers Protection System Interlocking Magnetic Separator 15-Aug-16 18 Conveyor Belt System

19. Synthetic rubber. It may be 4ply,5ply,6ply. 4 ply means 4 nylon net in between 2 mm thick rubber coating is used. A belt of 1000 mm width is used. Width varies from 500 mm -1400 mm. 15-Aug-16 19 Construction of Conveyor Belt Net Strength = 600N 1000 mm

20. 15-Aug-16 20 Conveyor Belt Drive System Motor G / B Fluid Coupling Filled with 3/4th oil Fusible plug Head End Pulley Tail End Pulley Speed before crusher 2.4 m/sec Speed After Crusher 2.7 m/sec Belt Speed

21. 15-Aug-16 21 IDLERS Carry Side Return Side Self Alignment Impact Return Roller Return Adjustment Roller ( Installed after every 25m ) Below Discharge chute ( rubber coating ) 35 °

22. Vibrating feeder -the coal stored in a huge hub is collected on the belt through vibrations created by vibrating feeders. Flap gates -these are used to channelize the movement of coal. Metal detector -these detect the presence of any ferrous and non ferrous metal in the coal.it consists of transmitter and receiver. Reclaim hopper -process of taking coal from the dead storage for preparation and feeding to reclaim hoppers. 15-Aug-16 22 EQUIPMENT USED IN COAL HANDLING PLANT

23. 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. 15-Aug-16 23 Protection System

24. Three Stage Crushing System is used in Plant. 1.Double Roll Crusher 2.Rotary Breaker Crusher 3.Impact Crusher 15-Aug-16 24 Crushing Mechanism In CHP W / T No.4 DRCR RBCR Impact 250 mm 80 mm 600 mm 20-25 mm Stage 1 Stage 2 Stage 3

25. 15-Aug-16 25 Double Roll Crusher ( DRCR ) Teeth Roller 300 mm

26. 15-Aug-16 26 Rotary Breaker Crusher ( RBCR ) Striking Plate Hole of diameter 100 mm 250 mm 80 mm Stone shell

27. 15-Aug-16 27 Impact Crusher Hammer 30 mm Rotor Coal

28. Fenglian Song,” Analysis of Optimization Configuration for Coal Handling System in Large Power Plant”, 2012, IEEE   Technical paper on “Quality Assured Maintenance Management For Coal Handling Plant” by Makarand Joshi , in M-News Edition 28 of Plant Maintenance Resource Center   Technical paper on “Maintenance Method For Critical Equipment's Of Coal Handling Plant” by Makarand Joshi , in M-News Edition 28 of Plant Maintenance Resource Center International Journal of Advanced Engineering Technology E-ISSN 0976-3945 IJAET/ Vol.II / Issue IV/October-December, 2011/393-395 DUST MANAGEMENT AT COAL HANDLING PLANT OF ATHERMAL POWER PLANT by Ankush Kumar, Sumit Chakraborty, Ankit Kumar , Saad Parvez & Dr. Marouf Wani   Girja Lodhi, "Operation and Maintenance of Crusher House for Coal Handling in Thermal Power Plant," International Journal of Mechanical Engineering and Robotics Research, Vol. 2, No. 4, pp. 449-455,  15-Aug-16 28 REFERENCES

29. 15-Aug-16 29