CONSTRUCTION

AND WORKING OF
COAL HANDLING

5/10/2018
PLANT

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 5/10/2018
PRESENTED BY

Shrikant S.
Khating

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INDEX

 Introduction.

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 Availability of Coal in India.

 Transportation of Coal.

 Analysis of Coal.

 General Layout of CHP.

 CHP Auxiliary And Equipments

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INTRODUCTION

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 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.
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AVAILABILITY OF COAL IN INDIA.
 Mostly E and F grade coal used in India.
 Blending Is Done To get Average D Grade.

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Grade C.V. % Ash + Moisture
( K Cal / Kg. )

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

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F 2401-3360 40.14 - 47.10
TRANSPORTATION OF COAL Best and Cheap
facility at Doorstep
5 ways of Transportation.

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Available only for
• 1. Railways. TPS nearer to coal
mines
• 2. Ropeways.
• 3. Roadways.
• 4. waterways. Fear of thief

• 5. Airway.
waterway may not be possible
till TPS and Problem of
recalling arises if coal dip in
water
Have to build Runway
near TPS which is very
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costly.
BY RAIL WAY
 80-90% of the requirement is fulfilled by this way.

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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.
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 Rate of demurrage is Rs.100 / wagon / hr.

ANALYSIS OF COAL

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 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.

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GENERAL LAYOUT OF CHP

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Wagon Tippler Crusher House
Hopper

Feeder Surge
Hopper

Conv. Belts Vibrating

Screens

Crushers
Tripper Trolley

Bunkers 9
CHP Auxiliaries

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OPERATIONAL CYCLE

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Bunkering Cycle

Stacking Cycle

Reclaiming Cycle

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BUNKERING CYCLE

From W/T

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Crusher House
Surge Hopper

Vibrating
Feeder

Crusher
Bunkering
Belts

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Bunkers
STACKING CYCLE

From W/T

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Crusher House
Coal Is not required if
bunker is full or Due any
maintenance

By-Passed Coal
Bunkering Stacking Belts
Belts

Crushed 13
Bunkers
Yard
RECLAIMING CYCLE
If Outer Supply of
coal Is Not Present
From W/T

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Crusher House
Non-
Crushed
Yard

Reclaiming Belts
Stacked Coal
Bunkering
Belts

Crushed
Bunkers 14
Yard
WAGON TIPPLER

 These are used to unload the coal wagons into coal

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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.

Wt of the coal =Wt. of loaded wagon – Wt. of empty

wagon

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WAGON TIPPLER DRIVE SYSTEM

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Motor

Thruster
Brake

G/B

Pinion

Spur Gear 16
 GENERAL LAYOUT OF W/T

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Wagon tippler

Hopper
Mesh of 250 mm * 250 mm

Vibrating Feeder

Conveyor Belt
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To crusher
House
EQUIPMENT USED IN W/T

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 Water Sprinkler System.
 Dust Extraction System.

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CONVEYOR BELT SYSTEM

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 Construction of Conveyor Belt
 Conveyor Belt Drive System

 Counter Weight

 Idlers

 Protection System
 Interlocking
 Magnetic Separator

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 CONSTRUCTION OF CONVEYOR BELT

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 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.

Strength = 600 N

1000 mm
Net

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 CONVEYOR BELT DRIVE SYSTEM
Fusible

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Head End
plug Pulley

Motor G/B

Fluid Coupling
Filled with 3/4th oil

Tail End Pulley

Belt Speed 21
oSpeed before crusher 2.4 m/sec
oSpeed After Crusher 2.7 m/sec
COUNTER WEIGHT
Idlers Conveyor
Head End

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Belt
Pulley
Tail End
Pulley

Return Idlers

Take-up Pulley
Railing
Counter Weight

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 IDLERS

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Carry Side Return Side

Self Alignment Impact Return Roller Return Adjustment

Roller
( Installed after Below Discharge
every 25m ) chute
( rubber coating )

35° 23
ANGLE OF IDLERS

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Angle Merits Demerits

20° No middle idler More Coal

is overloaded Derailed

35° Coal not Derail. Middle idler is

overloaded

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PROTECTION SYSTEM

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 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.

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CRUSHING MECHANISM IN CHP

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 Three Stage Crushing System is used in Plant.
 1.Double Roll Crusher
 2.Rotary Breaker Crusher
 3.Impact Crusher

W / T No.4

600 mm

Impact Stage 3
DRCR RBCR
250 mm 80 mm

Stage 1 Stage 2 26
20-25 mm
DOUBLE ROLL CRUSHER ( DRCR )

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Roller

Teeth

300 mm

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ROTARY BREAKER CRUSHER ( RBCR )

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250 mm
Striking
Plate
Hole of diameter 100
mm

Stone
shell

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80 mm
 IMPACT CRUSHER

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Coal

Hammer

30 mm Rotor

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