Study and detailed Review of Coal Handling Plant.pptx

coal handling plant

1. COAL HANDLING PLANT & its safety equipments 10/18/2025 1

2. PRESENTED BY D.CHAKROBORTY 10/18/2025 2

3. index Introduction. Availability of Coal in India. Transportation of Coal. Analysis of Coal. General Layout of CHP. CHP Auxiliary And Equipments 10/18/2025 3

4. Introduction 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. 10/18/2025 4

5. Availability of Coal In India. Mostly E and F grade coal used in India. Blending Is Done To get Average D Grade. 10/18/2025 5 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. Transportation of Coal 5 ways of Transportation. 1. Railways. 2. Ropeways. 3. Roadways. 4. waterways. 5. Airway. 10/18/2025 6 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. 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. 10/18/2025 7

8. 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. 10/18/2025 8

9. General Layout Of CHP 10/18/2025 9 Wagon Tippler Crusher House Bunkers Tripper Trolley Conv. Belts Vibrating Screens Crushers Feeder Surge Hopper Hopper

10. 10/18/2025 10

11. Operational Cycle 10/18/2025 11

12. Bunkering Cycle 10/18/2025 12 Bunkers From W/T Bunkering Belts Surge Hopper Vibrating Feeder Crusher House Crusher

13. Stacking Cycle 10/18/2025 13 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

14. Reclaiming Cycle 10/18/2025 14 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

15. 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. 10/18/2025 15 Wt of the coal =Wt. of loaded wagon – Wt. of empty wagon

16. Wagon Tippler Drive System 10/18/2025 16 Motor Pinion Spur Gear Thruster Brake G / B

17. Wagon tippler Mesh of 250 mm * 250 mm Hopper Vibrating Feeder Conveyor Belt To crusher House General Layout Of W/t 10/18/2025 17

18. Equipment Used In W/T Water Sprinkler System. Dust Extraction System. 10/18/2025 18

19. Conveyor Belt System Construction of Conveyor Belt Conveyor Belt Drive System Counter Weight Idlers Protection System Interlocking Magnetic Separator 10/18/2025 19

20. 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. 10/18/2025 20 Net Strength = 600 N 1000 mm

21. Conveyor Belt Drive System 10/18/2025 21 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

22. Counter Weight 10/18/2025 22 Return Idlers Idlers Counter Weight Head End Pulley Tail End Pulley Conveyor Belt Railing Take-up Pulley

23. Idlers 10/18/2025 23 Carry Side Return Side Self Alignment Impact Return Roller Return Adjustment Roller ( Installed after every 25m ) Below Discharge chute ( rubber coating ) 35 °

24. Angle Of Idlers 10/18/2025 24 Angle Merits Demerits 20 ° No middle idler is overloaded More Coal Derailed 35 ° Coal not Derail. Middle idler is overloaded

25. 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. 10/18/2025 25

26. Crushing Mechanism In CHP Three Stage Crushing System is used in Plant. 1.Double Roll Crusher 2.Rotary Breaker Crusher 3.Impact Crusher 10/18/2025 26 W / T No.4 DRCR RBCR Impact 250 mm 80 mm 600 mm 20-25 mm Stage 1 Stage 2 Stage 3

27. Double Roll Crusher ( DRCR ) 10/18/2025 27 Teeth Roller 300 mm

28. Rotary Breaker Crusher ( RBCR ) 10/18/2025 28 Striking Plate Hole of diameter 100 mm 250 mm 80 mm Stone shell

29. Impact Crusher 10/18/2025 29 Hammer 30 mm Rotor Coal

30. SAFETY EQUIPMENTS 1 . PULL CORD S/W 2. ZERO SPEED S/W 3. BEST SWAY S/W 4. LOAD CELL 5. LOAD TOTALISER 6. METAL DETECTOR 7. DE-SYSTEM 8.TACHOMETER 9. VIBRATION ANALYSER 10. LIMIT S/W 10/18/2025 30

31. PULL CORD SWITCH 10/18/2025 31 Principle of Operation - The pull cord switch is used as a rope operated safety tripping switch for conveyor belts, i.e. When the rope is pulled the lever of the pc unit is operated which in turn, actuates a switch, thereby the conveyor is stopped. The switch lever will be manual reset type.

32. ZERO SPEED SWITCH 10/18/2025 32 Principle of Operation- Pairs of magnet are attached to the shaft or coupling to be monitored so that they rotate past a magnetic switch (pulse generator) and they operate the magnetic switch with their magnetic fields, without contact and without wear and tear. The magnetic switches used have a practically unlimited service life and are connected to a motion.  

33. Belt sway switch 10/18/2025 33 Belt Sway Switch- It is a protective switch for detecting the meandering (sway or deviation) of belt conveyors, and sends out an alarm signal and an emergency stop signal. Suited to be used for belt breakage prevention and ore falling prevention due to the belt sway. Widely used in iron and steel, cement and chemical plants, thermal power plants, etc., since it is essential for safety operation of belt conveyors.

34. Load cell 10/18/2025 34 A Load cell is a transducer that is used to convert a force into an electrical signal . This conversion is indirect and happens in two stages. Through a mechanical arrangement, the force being sensed deforms a strain gauge . The strain gauge measures the deformation ( strain ) as an electrical signal, because the strain changes the effective electrical resistance of the wire. A load cell usually consists of four strain gauges in a Wheatstone bridge configuration. Load cells of one strain gauge (quarter bridge) or two strain gauges (half bridge) are also available. [1] The electrical signal output is typically in the order of a few millivolts and requires amplification by an instrumentation amplifier before it can be used. The output of the transducer can be scaled to calculate the force applied to the transducer. The various types of load cells that exist include Hydraulic load cells, Pneumatic load cells and Strain gauge load cells.

35. Coal handling plant & its safety equipments 10/18/2025 35

36. Thank You. 10/18/2025 36