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COAL HANDLING PLANT
Introduction
Coal Handling Plant (CHP) is a plant which handles the coal from its receipt to
transferring or conveying it to Boiler House and storing in Raw Coal Bunkers
(R.C.Bunkers). Average size of Coal received in CHP is 300-400 mm, which is called
Received off Mine (ROM) size.
Functional Work in Coal Handling Plant (CHP):
In brief it can be stated that Coal Handling Plant performs the following main
functional work sequentially:
Receipt of coal in CHP from coal mines Different ways of Coal
Transportation from mines
Weighing of coal by Electronic Weighing Machine
Unloading of coal form wagon or truck by Wagon Tipplers
Controlling coal flow on conveyor belt by Vibrating Feeder
Transferring or conveying of coal to different points by Conveyor
Belts
Storing & Stacking of uncrushed coal in coal yard by Stacker cum
Reclaimer
Coal Screening for separating sized coal and by passing thecrusher by Vibrating Screen
Crushing it to required size Coal Crushers
Transferring & distributing the quanta of crushed coal to various
coal mill bunkers by Travelling Trippers
Major Equipments of CHP:-
1. Wagon Tipplers
2. Vibrating Feeders3. Conveyor Belts
4. Vibrating Screen
5. Coal Crushers
6. Travelling Trippers
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Auxiliaries in Coal Handling Plant
1. Electromagnetic Separators, Cross Belt Magnetic Separator
(CBMS) & Magnetic Pulley
2. Metal Detector
3. Dust extraction systems
4. Gas Extractor
5. Pull Cord
BASIC FUNCTIONAL LAYOUT OF CHP:
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BASIC FUNCTIONAL LAYOUT OF CHP:
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COAL HANDLING PLANT
1000 TPH Coal Handling Plant at Durgapur Projects Power Station, Extn. Unit #7 (1 x 300
MW) including Track Hopper with Paddle feeder, Crushing & Screening, Stacker cum Reclaimerand Belt Conveying System with associated Electrical, Civil & Structural and Utility work for
Durgapur Projects Limited.
1 X 300 MW Durgapur Project Power Station
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Wagon Tipplers:-These are the giant machines having gear boxes and motor assembly and are used
to unload the coal wagons into coal hoppers in very less time (e.g. 20 wagons/hr.
or more).
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Vibrating Feeders:-These are electromagnetic vibrating feeders or sometimes in the form of dragging
chains (Apron Type) Vibrating Feeder which are provided below the coal hoppers.
This equipment is used for controlled removal of coal from coal hoppers.
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Electromagnetic Vibrating feeding system
A vibratory feeding system includes a hopper, a tray and an electromagnetic vibrator. The hopper isdisposed above the tray so that components can flow from the hopper to the tray. The vibrator is
mounted to the tray. During operation, an electromagnet is rapidly energized and de-energized causing an armature of the drive assembly to be pulled in and released upto 7,200 times per minute, in turn imparting a vertical reciprocating vibration to the
support platform so that the tray can be vibrated to move components along the tray. The tray can
have a v-groove along which the plurality of components can flow.
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Belt Conveyor System:-
Belt conveyor System is a kind of machine that to transfer the material
continuously. It has the synthetic rubber belts which move on metallic rollers
called idlers with the help of belt drive (pulleys). It is used in Coal Handling Plant
for shifting of coal from one place to other places The belt works under the effect
of frictional force. It is not only the components to transfer the material, but also
the components to transfer the force.
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Conveyor Belt system consists of the following components:
1. Conveyor Belt- internal Cotton canvas or Synthetic canvas or metal wire
canvas impregnated with rubber covers on both face and back.
2. Pulley drive system having Drive or Head pulley with Motor, Tail Pulley, Bend
Pulleys & Snub Pulley
3. Idlers
4. Gravity Take up system or Belt tensioning system
5. Belt cleaning or wiping system
6. Gear Box
7. Fluid Coupling
CONVEYOR IDLERS
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TROUGHING IDLER
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TROUGHING TRAINING IDLERS
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IPMACT IDLER & ITS POLLAR
RETUTN IDLER
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Vibrating Screen
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Coal Crushers:-
We receive the coal in the form of odd shaped lumps. These lumps are to be
crushed to required size. These lumps are crushed by coal crushers.
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Trippers:-
These are the motorized or manually operated machines and are used for feeding
the coal to different coal bunkers as per their requirement.
Electromagnetic Separators:-
Electromagnets are used for removing of Iron and magnetic impurities from the
coal.
Dust Extraction System:-
This system is provided in CHP for suppression of coal dust in coal handling plant.
Gas Extractors:-
Gas extractors are provided at the bunker level to remove all types of poisonous
and non poisonous gases from the working area.
Operational Cycles:-
1. Normal Bunkering cycle.
2. Stacking cycle.
3. Reclaiming Cycle.
Normal Bunkering Cycle:-
Shifting of coal received from coal wagons directly to coal bunkers is normal
bunkering cycle.
Stacking Cycle:-
When there is no coal requirement at coal bunkers even then CHP has to unload
the received coal which is stacked at open ground called yard. This is stacking
cycle.
Reclaiming Cycle:-As and when coal wagons are not available the requirement of coal bunkers is
fulfilled from the stacked coal this is reclaiming cycle.
Weighing of Coal:-
Weighing of coal is carried out at wagon tippler. Weight of loaded wagon is taken;
after unloading the coal, weight of empty wagon is taken the difference of the two
will give the weight of the coal (normally 55-60 metric ton of coal come in each
wagon).
Payment of Coal:-Payment of coal is made to the coalmines as per the weighing of coal carried out
at their premises. However, if any dispute arises regarding weighing of coal same
is to be settled by the committee of both the parties.
Stone shells:-
Sometimes stone shells are received along with coal same has to be removed from
the coal before bunkering and is done sometimes manually or by different type of
machines.
If quantum of stone shells is beyond minimum limit the cost of the coal is
recovered from the coal mines against the quantity of stone shells received from
them.
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Chemical Analysis of Coal:-
Sample of coal is randomly collected from each rake by concerned MSEB staff 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.