Coal Handling System Guide

Coal Handling Plant (CHP)
COAL HANDLING SYSTEM:

Coal Handling Plant is plant which handles the coal from its receipt point (Coal mines) to transporting it to Boiler and store in
coal Bunker. It also processes the raw coal to make it suitable for Boiler operation.
A typical coal handling plant in any power plant shall have the following processes in sequence depending on the capacity of
the plant.
1.
2.
3.
4.
5.
Unloading Process
Feeding Process
Screening Process
Crushing Process
Stacking & Reclaiming Process
6. Storing in Bunker
1. Unloading Process:
The mode of transporting coal and limestone from the mines to the power plant is determined by the location of the plant
relative to the location of the mines.
Following are the ways of transportation from mines to Plant
1.
2.
3.
4.
5.
Rope Ways
Road Ways
Railways
Water ways
Air ways
CIA-GLOCAL VENTURE LLP. 418, Vipul Trade Centre, Sector-48, Sohna Road, Gurgaon122018,
Ph: 0124-, Email: assistance@cia-glocal.com
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Rope way is used where Plant is very nearer to Mines.

Road way is used where Plant is far away from the plant and no railway or water connectivity is there. Cost of the coal
transportation by road is much higher than Rail and waterway.
For long distances and where ocean or river delivery is possible, barge or ship delivery of coal is usually the most practical
mode, with the lowest cost but where ocean or river delivery is not possible then Rail transportation is the best mode of
transportation from mines to Plant.
Airway is very costly way of transportation of coal from mines to plant, in India we are not used this mode of transportation.
80-90% of coal transportation in India is by Railway. The coal received at power station may be unloaded by
means of track hopper or wagon tippler or by combination of both depending on the type of wagons
(BOBR or Box-N wagons) in the coal rakes expected to be received at the station.
As mentioned above, the coal received at power station may be unloaded by means of wagon tippler
or track hopper or by combination of both depending on the type of coal rakes to be used for
transportation of coal to the station. Generally coal rake consists of 59 wagons, each wagon carrying
payload of 60 tons. The two unloading systems are briefly described below:
Track hopper Unloading System:
The BOBRN wagons will be discharging the material through the discharge gates provided at the
bottom of the wagons. This type of unloading system consists of track hopper below the rail track,
mechanism for opening the pneumatic gates of the wagons and feeders below the track hopper. The
loaded rake will be brought to the track hopper by the main line locomotive and the same locomotive
will stay connected to the rake while the unloading operation is in process and the rake will be
hauled out of the plant. It is not necessary to disconnect the loco from the rake unlike in the case of
wagon tippler system.
The length of the track hopper adopted in most of the Indian plants is about 200 m and the capacity
of this hopper will be suitable for storing one rake material. The track hopper will be of RCC
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construction and suitable liner will be provided depending on the abrasiveness of the material
handled. Steel grid of about 250 mm square will be provided over the track hopper.
Wagon Tippler Unloading System:

The coal received from Box-N wagons is unloaded in underground RCC hoppers by means of rota side
type wagon tipplers. Side arm chargers are employed for placement of wagons on the tippler table
and removal of empty wagon from tippler table after tippling. Apron feeders are employed under
each wagon tippler for extracting coal from wagon tippler hopper and feeding onto underground
reclaim conveyors. Belt weigh scales are provided on these conveyors for measurement of coal flow
rate. Provision is kept for shunting locomotives for placing the rakes in position for the side arm
charger to handle and begin unloading operation.
2. Feeding Process:
The feeding process involves continuous and control coal flow to meet the plant requirement.
Various types of feeders are used in these processes. Feeder protects the belt conveyors from
damage by feeding the material into the belt conveyor from storage hoppers, at a controlled rate.
These feeders are located below hoppers for feeding material at uniform rate to belt conveyor.
The feeders, which are mainly used in CHP plant are listed below.
Belt feeder
Apron feeder
Vibrating feeder
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3. Screening Process:
There are three basic types of screening process
Scalping
Fines removal
Grading
Scalping:
For scalping operations at the coarse end of particle distribution, very high screening capacities can
be achieved since most of the particles are much smaller than the screen opening and pass through
quite easily.
Fine Removal:
Vibrating screens are of gravity feed type, being sloped downward from the feed to discharge end. A
high frequency low magnitude vibration is given to the screen by an electric vibrator or other means.
The purpose of vibration is to keep the meshes clear of wedged particles and stratify the coal so that
fine particles come down in contact with the screen.
Grading:
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The coal is feed on the rollers, which are continuously rotate. While rotating these shaft, transfers the
coal from feeding end to crushing process end. The required size of coal is passed through gap of
roller shafts. The remaining coal is passed through rollers to crusher.
4. Crushing Process:
Coal unloaded in the wagon tippler hoppers/track hoppers is conveyed to crusher house by belt
conveyors via pent house and transfer points depending on the CHP layout. Suspended magnets are
provided on conveyors at pent house for removal of tramp Iron pieces. Metal detectors are also
provided to detect non-ferrous materials present in the coal before crushers. In case the sized coal is
received, then the coal is sent directly to stockyard and the crusher is by-passed. Coal sampling unit
is provided to sample the uncrushed coal.
The size of the coal received is normally (-) 300 mm which is sized in crushers from (-) 300 mm to (-)
20 mm. Screens provided upstream of the crushers screen out (-) 20 mm coal from the feed and (+)
20 mm coal is fed to the crushers.
There are four basic processes to reduce the size of coal.
Impact
Attrition
Shear
Compression
In CHP, crushing process is combination of Impact and Attrition process. Some process involves
Compression crushing.
Impact Crushing Process:
The bottom of the Reversible Impactor is open, allowing sized materials to pass through almost
instantaneously. Liberal clearance between hammers and the breaker blocks eliminates attrition.
Crushing is by impact only. In crushing, impact is the sharp, instantaneous impingement of one
moving object against another. Both objects may be moving, or one object may be motionless.
Attrition Crushing Process:
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When a Non-Reversible Hammer mill is used for reduction, material is broken first by impact between
hammers and material and then by shear and a scrubbing action (attrition) of material against
screen bars.
Shearing Crushing Process:
Shear is a trimming or cleaving action that is usually combined with other methods: single-roll
crushers, for example, use shear, impact and compression methods combined. Shear crushing is
usually called for under these circumstances: When material is somewhat friable and has relatively
low silica content.
Compression Crushing Process:

This crushes by compression without rubbing. Hinged overhead and on the centerline of the crushing
zone, the swinging jaw meets the material firmly and squarely. There is no rubbing action to reduce
capacity, to generate fines or to cause excessive wear of jaw plates.
5. Stacking & Reclaiming Process

Crushed coal is sent to stockyard when coal bunkers are full. Stacking/ reclaiming of coal is done by
bucket wheel type stacker-cumreclaimer moving on rails. The stacker-cum reclaimer can stack coal
on either sides of the yard conveyor. During stacking mode coal is fed from conveyors on boom
conveyor and while in reclaim mode, boom conveyor discharges coal on the yard conveyor for
feeding coal to bunkers through conveyors and transfer points. The yard conveyor can be reversible
type depending on layout requirement.
When direct unloading from rakes is not in operation, coal is reclaimed by the stacker cumreclaimer and fed to the coal bunkers. Emergency reclaim hopper (ERH) can be provided to reclaim
coal by dozers when stacker cumreclaimer is not in operation. Emergency reclaim hopper can also
be used for coal blending. Coal stockpile is provided with required storage capacity depending on
location of plant vis--vis coal source.
Metal detectors and in-line magnetic separators are also provided before feeding to bunkers for
removal of metallic ferrous tramp from reclaimed crushed coal. Coal sampling unit is provided to
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sample crushed coal of (-) 20 mm size. Belt weigh scales are also provided, on conveyors for
measurement of flow rate of as fired coal.
Stacking:
In this process coal from unloading area shall be stored /stacked in a yard for future use. This shall be
done by using belt conveyor with telescopic chute arrangement
Reclaiming
In this process the stacked coal shall be reclaimed for sending to boiler bunkers. Reclaiming shall be
done by bulldozer and grizzly hopper arrangement. Both the process shall be combined and
executed by Stacker Reclaimers
6. Bunkering Process:
This process involves feeding of bins/bunkers and maintaining the level of these bins.
From the conveyor belt the coal is discharged into bunker or bins with the help of trippers.
The tripper is provided with wheels, which moves on rails parallel to conveyor on each side. It can be set in one position or
made to travel slowly backward or forward between stops; to discharge the quantity of coal at desired location.
Motorized trippers are usually used where continuous and uniform distribution of coal along the conveyor is required or where
frequent forward or reverse movement is required
Trippers having rigid welded steel frame to resist shock and minimize distortion. One way or two way discharge chutes are
provided. The bifurcating chute permits the flow and discharge of coal to the desired side.
Typical Flow Diagram of Coal Handling Plant:
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Coal Handling Plant (CHP)