Coal handling plant

1. 30 June 2013 1
Prsentation
On
Coal Handling
Plant
(CHP)

2. Presented by:-
 Ronak Thakre
30 June 2013 2

3. Contents:-
 Introduction..
 What is actually CHP ??
 Main Target Of CHP…
 General Layout Of CHP…
 Grading Of coal….
 Constituents Of Coal…
 Consumption Of Coal at KTPS & CSTPS…
 Section Of CHP…
 CHP auxillary & Equipments….
 Coal feeders…
 Coal crushers…
 Operating sequence of CHP…
 Problem faced in CHP….
30 June 2013 3

4. Introduction:-
• Objective of CHP is to supply the quanta of processed
coal to bunkers of Coal mills for Boiler operation and to
stack the coal to coal storage area.
• Coal is a hard black or dark brown sedimentary rock
formed by the decomposition of plant material, widely
used as a fuel.
• A piece of coal called Coal Lumps. Mostly E and F grade
coal used in India.
• 5 ways of Transportation of Coal is
1. Railways. (90% used)
2. Ropeways.
3. Roadways.
4. Waterways.
5. Airway.
30 June 2013 4

5.  The sizes of coal lumps is about to the
600mm.
 This coal is fed to single rotary crusher and
after that the size become 300mm.
 This coal is again fed to the double rotary
crusher and the size become 80mm.
 This coal is again fed to the crusher and the
size become less than 20 mm or 20mm.
 Then this coal is fed to the coal mill for
pulverization.
 Even when the bunker is full this coal is used
for stacking or storage of coal in coal storage
area.
30 June 2013 5

6. What is CHP??
 CHP is (C- Coal, H- Handling, P- Plant) a plant
which handles the coal from its receipt to
transporting it to Boiler and store in Bunkers. It also
processes the raw coal to make it suitable for Boiler
Opeartion.
 Extent of work: - In brief we can say that receipt of
coal from coal mines, weighing of coal, crushing it
to required size and transferring the quantity of coal
to various coal mill bunkers.
 This is the responsibility and duty of the CHP and
its staff.
30 June 2013 6

7. Main Target:-
 To Receive , Process , Store and Feed
coal.
 Bunkering of Coal.
 Unloading of Coal wagon.
 Stacking Of Coal.
30 June 2013 7

8. 30 June 2013
GENERAL LAYOUT OF CHP
Wagon tippler
Crusher House
Bunkers
Tripper Trolley
Conv. Belts Vibrating
Screens
Crushers
Feeders Surge
Hopper
8

9. 30 June 2013
GRADES OF COAL
SR.NO. GRADE CAL. VALUE
Kcal/Kg.
1 A More Than 6200
2 B 5601 - 6200
3 C 4941 - 5600
4 D 4201 - 4900
5 E 3361 – 4200
6 F 2401 – 3360
7 G 1301 – 2400
8 H Below 1300 9

10. CONSTITUENTS OF COAL
 Carbon :- 42.9%
 Hydrogen :- 2.96%
 Nitrogen :- 0.91%
 Sulphur :- 0.33%
30 June 2013 10

11. 30 June 2013
CONSUMPTION OF COAL
GENERATION PER HOUR PER DAY/SET
210 MW 120 MT 3000 MT
500 MW 300 MT 7000 MT
11

12. CONSUMPTION OF
COAL(KTPS)
GENERA
TION
PER
HOUR
PER
DAY/
SET
No. OF
SETS
TOTAL
REQRT.
IN mt.
120 MW 80 MT 2000
MT
4 8000
210 MW 120 MT 3000
MT
3 9000
TOTAL 420 MT 10000
MT
7 17000
30 June 2013 12

13. 30 June 2013
CONSUMPTION OF
COAL(CSTPS)
G ENER A
TIO N
PER
HO UR
PER
D AY/
SET
NO . O F
SETS
TO TAL
210 120 MT 3000
MT
4 12000
500 300 MT 7000
MT
3 21000
TOTAL 420 MT 10000
MT
7 33000
STORAGE CAPACITY OF CO AL Y ARD = 5,00,000 M T
ESTIM ATED COAL REQUREM ENT = 7 M ILLION TON. 13

14. Sections of CHP:-
Management of Coal
Transportation of Coal
Handling of Coal
30 June 2013 14

15. Management of Coal:-
• Central government
• CIL
• WCL
• Railway
• Mah.State
• MSEB
30 June 2013 15

16. 30 June 2013
TRANSPORTATION OF
COAL
MODE OF
COAL
TRANSPORT
1. ROADWAYS
2. RAILWAYS
3. ROPEWAYS
16

17. 30 June 2013
1) ROADWAYS
Coal is carried in trucks.
8-10 mt coal per truck.
Requires more time and manpower.
Coal mines should be near to PS
(100-150 km).
Coal is lost / waste in transit.
Hence not in use for large power stations.
17

18. 30 June 2013
2) RAILWAYS:-
◦ Unloaded with the help of WAGON TIPPLER
◦ One Rack consist of 52-56 Wagons.
◦ 13/25 wagons can be tippled in an hour.
◦ Each wagon contains 55-58 MT of coal.
◦ Wagon movements are controlled by “Bettle
Chargers”
◦ Demurrage charges on racks.(11 ½ hrs.)
◦ Most popular mode of transport.
18

19. 30 June 2013
WAGON TIPPELERS
WAGON
TIPPLER
SIDE
TIPPLER
ROTORY
TIPPLER
19

20. 30 June 2013
ROTASIDE
TIPPLERS
 140 to 150 Degree Tilting ROTASIDE ELECON
MAKE TIPPLERS
 CAPACITY : 13 Wg/HR.
 Wagon is unloaded in side hopper
IN HAILOUT HAUL
BETTLE CHARGERBETTLE CHARGER
LOADED WAGONSUNLOADED WAGONS
UNLOADING HOPER
20

21. ROTASIDE TIPPLERS
 CYCLE OF OPERATION :
◦ 1. Gross weight----------- 15 Sec.
◦ 2. Tippling ( 1400 )-------- 90 sec.
◦ 3. Pause--------------------- 5 Sec.
◦ 4. Return--------------------- 90 Sec.
◦ 5. Tare weight-------------- 15 Sec
◦ =============================
TOTAL TIME REQD.----- 210 Sec.
30 June 2013 21

22. 30 June 2013
RING / ROTORY TIPPLERS
High capacity Tipplers
Capacity : 25 Wagons/Hr.
Time Reqd. : 60 Sec.
Wagon is unloaded in hopper under
the tippler.
22

23. 30 June 2013
TRACK HOPPERS
Provided for 500 MW Units at CSTPS.
Unloaded in track hoppers
Holding capacity of track hopper =
4500 MT
Max. size of coal = 600 mm.
BOBR wagons are used.
◦ (Bottom Opening Bogie on Rails)
23

24. 3) ROPEWAYS
Coal Mines should be in vicinity of Power
Station
Assured supply of coal @ 100 - 250 T/H.
Economical
MSEB Property.
High Maint.
30 June 2013 24

25. 30 June 2013
Type of ROPEWAYS:-
TYPE OF
ROPEWAYS
MONO-RAIL BI-CABLE
BUCKET
TYPE
TRAM CAR
TYPE
25

26. MONOCABLE ROPEWAY
Cap : 100 T/h
Bucket Cap. :- 1.0 ton
Haulage RopeBuckets
30 June 2013 26

27. 30 June 2013
Bi-CABLE ROPEWAY
(Bucket Type)
Track Rope Haulage Rope
Bucket
CAP : 200-275 T/H
BUCKET : 1.8 T
27

28. 30 June 2013
Bi-CABLE ROPEWAY
( Tram Car Type )
Track Rope
Haulage
Rope
Line Cap : 250 T/H
Car Cap : 2.5 T/H
Return Side Track Rope
28

29. 30 June 2013
GROUP OF ROPEWAYS
A B
D
P C
E
KORADI
KHAPARKHEDA
PATAN
SAWANGI PIPLA VALANI SILEWARA
PA -MONO-CABLE(BUCKET)
AB -BI-CABLE(TRAM CAR)
BD -BI-CABLE9TRAM CAR)
CD -BI-CABLE(BUCKET)
DE -BI-CABLE(TRAM CAR)
LENGTH- 4.0 KM
BUCKETS - 92 (16 Parking)
LINE CAP- 75 T/H
BUCKET CAP-1.0 T
Hal.Rope - 33 mm
Speed - 168 m/min
LENGTH- 1.5 KM
BUCKETS- 32
LINE CAP-200 T/H
BUCKET CAP-2.5 T
Speed - 600 ft/min
HR-25 / TR-43/32 mm.
LENGTH-1.75 KM
BUCKETS- 63(57 Parking)
LINE CAP-200 T/H
BUCKET CAP-1.8 T
Speed - 650 ft/min
HR-25 / TR-48/33 mm
LENGTH-3.0 KM
BUCKETS-129
LINE CAP-200 T/H
BUCKET CAP-2.5 T
LENGTH- 3.0 KM
BUCKETS- 67
LINE CAP- 200 T/H
BUCKET CAP-2.5 T
29

30. Equipments used in CHP :-
1. Pull chord switch
2. Vibrating feeder
3. Flap gates
4. Magnetic separator
5. Belt weightier
6. Reclaim hopper
7. 5. Metal detector
30 June 2013 30

31. Equipments used in CHP :-
1. Pull chord switch
A series of such switches are arranged in series at a
1m distance on the side of conveyor belt. The power supply to rotor of
the conveyor belt is established only if all switches in series are
connected.
2. Vibrating feeder
The coal stored in a huge hub is collected on the belt
through vibrations created by the vibrating feeder.
3. Flap gates
These are used to channelize the route of coal
through another belt in case the former is broken or unhealthy. The flap
gates open let the coal pass and if closed stop its movement.
4. Magnetic separator
These are used to separate the ferrous impurities
from the coal.
30 June 2013 31

32. 30 June 2013 32
5. Metal detector
These are detect the presence of any ferrous and
non-ferrous metal in the coal and sends a signal to a relay which
closes to seize the movement of belt until the metal is removed. It
basically consists of a transmitter and a receiver.
The transmitter consists of a high frequency oscillator,
which produces a oscillations of 1500 Hz at 15V. The receiver
receives this frequency signal. If there is any presence of metal in the
coal. Then this frequency is disturbed and a tripping signal is send to
relay to stop the conveyor belt.
6. Belt weightier
It is used to keep an account of the tension on the
belt carrying coal and is moves accordingly to release tension on the
belt.
7. Reclaim hopper
Reclaimation is a process of taking coal from the
dead storage for preparation or further feeding to reclaim hoppers.
This is accomplished by belt conveyors.

33. CHP: Auxillaries
 Conveyor System
 Wagon Tipplers
 Coal feeders
 Crushers
 Coal trippers
 Protection System.
 Interlocks
 Operating Cycle
30 June 2013 33

34. 30 June 2013
Conveyor System
 Conveyor Belts
 Idlers
 Pulleys
34

35. 30 June 2013
Conveyor Belt
System
. HEAD PULLEY
TAIL PULLY
CONV. BELT
35

36. 30 June 2013
Conveyor Belt
System
HEAD PULLEY
TAIL PULLY
IDLERS
CENTRE AXIS
36

37. IDLERS
 Consists of 3 rollers
 Rollers are fitted with bearings/Life
sealed bearings.
 Profile makes an arc of a circle to
avoid sharp bends to increase belt life.
 Fitting arrangement : 2 types
 Fixed
 Detachable

38. IDlERS : Diagram
Roller
Conv.Belt
Brackets
Return Idler

39. PULLEYS :
 These are of heavy cast iron
 Driving pulleys are faced with ferodo
or similar frictional materials.
 The diameter of pulleys are large
enough to reduce the belt stresses.
 Width of the pulleys are 150 mm more
than belts.

40. SNUB PULLEYS :
 To relieve load on adjacent return idler
 To increase arc of contact with the
main pulley avoiding belt slipping.
Snub
Pulley
Return Idlers
Conv. Belt
Driving
Pulley

41. 30 June 2013
CONVEYOR BELTS
 Construction:
 Rubber+ Cotton Threads.
 Rubber + Fiber Threads
 Rubber + Steel Wires
 Ply Rating :
 4 Ply
 5 Ply
 6 Ply
41

42. BELTS : Ply Rating
1ply
2 ply
3 ply
FIBRE
30 June 2013 42

43. 30 June 2013
Belts : Quality
Long Life
Strength
Toughness
Light
Elastic
Pliability
43

44. 30 June 2013
BELTS : Labeling
1050/48/5/3/1.5/B/ L
WIDTH WT/ UNIT
LENGTH
NO.OF.
PLY
TOP RUBBER
THICKNESS
BOTTOM
RUBBER
THICKNESS
CLASS
LENGTH
900 mm
1050 mm
1200 mm
1400 mm
44

45. Interlocks:
 Whenever a belt trips , all earlier
belt trips along with the
associated Coal feeder.

46. 30 June 2013
COAL FEEDERS
 Vibrating Feeders
 Vibrating Screens
46

47. 30 June 2013
VIBRATING FEEDERS
 Provided at Coal input points
 Electro-magnetic type
 Coal feeding rate can be monitored as
per requirement
47

48. 30 June 2013
VIBRATING SCREENS
• Mechanical
• Fixed rate of feeding
• In Crusher House
Eccentricity
Vibrating Screen
Driving Unit
Coal
Bypass
To
Crusher
48

49. 30 June 2013
COAL CRUSHERS
 Primary Crushers : up to 600 mm
 Secondary Crusher : 600 to 100 mm
 Final Crushers : Up to 25 mm
49

50. 30 June 2013
OPERATING SEQUENCE OF
CHP
 DIRECT TO BUNKER
 DIRECT TO STACK
 STACK TO BUNKER (
RECLAIMING)
50

51. 30 June 2013
PROBLEMS FACED IN CHP
 DESIGN PROBLEMS :
◦ Cal. Value
◦ Ash %
 RAINY SEASON PROBLEMS :
◦ Chute choke ups
◦ Mud
◦ Coal yard -Slurry formation
 OTHER MISCH. PROBLEMS :
◦ Snapping of belts/ropes
◦ Derailment of coal wagons
◦ Oversized coal / Muddy Coal.
51

52. Conclusion:-
 In this way we conclude that CHP is
the heart of any thermal power plant.
 without CHP we can not imagine any
thermal power plant which generate
electricity.
 In this way CHP is essential need of
TPS.
30 June 2013 52