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7/21/15

CONSTRUCTION
AND WORKING OF
COAL HANDLING
PLANT

INDEX
Introduction.
Availability of Coal in India.
Transportation of Coal.
Analysis of Coal.
General Layout of CHP.
CHP Auxiliary And Equipments

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INTRODUCTION

What is CHP?
CHP (C- Coal, H- Handling, P- Plant)
Which properly handles the coal from its
receipt to transferring it to bunkers.

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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.

AVAILABILITY OF COAL IN INDIA.

Mostly E and F grade coal used in India.
Blending Is Done To get Average D Grade.

C.V.

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Grade

% Ash + Moisture

( K Cal / Kg. )
A

> 6200

19.57

5601-6200

19.57 - 23.97

4941-5600

23.92 - 28.69

4201-5940

28.69 - 34.05

3361-4200

34.06 - 40.14

2401-3360

40.14 - 47.10

TRANSPORTATION OF COALBest
5 ways of Transportation.

1. Railways.
2. Ropeways.
3. Roadways.
4. waterways.
5. Airway.

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and Cheap
facility at Doorstep

Available only for TPS

nearer to coal mines

Fear of thief

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

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.

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GENERAL LAYOUT OF CHP

Crusher House

Hopper

Feeder

Surge
Hopper

Vibrating
Screens

Conv. Belts

Crushers
Tripper Trolley
Bunkers

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Wagon Tippler

CHP Auxiliaries
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Operational Cycle
Wagon Tippler
Conveyer Belt System
Crushing Mechanism In CHP

OPERATIONAL CYCLE
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Bunkering Cycle

Stacking Cycle

Reclaiming Cycle
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BUNKERING CYCLE
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From W/T

Crusher House
Surge Hopper

Vibrating Feeder
Crusher

Bunkering
Belts

Bunkers

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STACKING CYCLE
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From W/T
Crusher House
Coal Is not required if
bunker is full or Due any
maintenance

By-Passed Coal

Bunkering
Belts

Stacking Belts

Bunkers

Crushed
Yard

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RECLAIMING CYCLE
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From W/T

If Outer Supply of
coal Is Not Present

Crusher House
NonCrushed
Yard
Reclaiming Belts

Stacked Coal

Bunkering
Belts

Bunkers

Crushed
Yard

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WAGON TIPPLER

Weighing of coal is carried out at wagon tippler.

Normally 55-60 metric ton of coal come in each wagon.

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These are used to unload the coal wagons into coal

hoppers in very less time (e.g. 20 wagons/hr. or more).

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

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GENERAL LAYOUT OF W/T

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Wagon tippler

Hopper

Mesh of 250 mm * 250 mm

Vibrating Feeder

Conveyor Belt
To crusher
House

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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
Net

1000 mm

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CONVEYOR BELT DRIVE SYSTEM

Motor

Head End Pulley

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Fusible
plug
G/B

Fluid Coupling

Filled with 3/4th oil

Tail End Pulley
Belt Speed
oSpeed before crusher 2.4 m/sec
oSpeed After Crusher 2.7 m/sec

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COUNTER WEIGHT
Conveyor Belt
Tail End Pulley

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Head End Pulley

Idlers

Return Idlers
Take-up Pulley
Railing

Counter Weight

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IDLERS

Self Alignment
( Installed after
every 25m )

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Carry Side

Return Side

Impact
Below Discharge
chute
( rubber coating )

Return Roller

Return Adjustment
Roller

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ANGLE OF IDLERS

Merits

Demerits

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No middle idler
is overloaded

More Coal
Derailed

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Coal not Derail.

Middle idler is
overloaded

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Angle

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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

Three Stage Crushing System is used in Plant.
1.Double

Roll Crusher
2.Rotary Breaker Crusher
3.Impact Crusher

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W / T No.4
600 mm
DRCR

Stage 1

250 mm

RBCR

Stage 2

80 mm

Impact

20-25 mm

Stage 3

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DOUBLE ROLL CRUSHER ( DRCR )

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Roller
Teeth

300 mm

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ROTARY BREAKER CRUSHER ( RBCR

)

Striking
Plate

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250 mm

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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Thank You.

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