gmr - ports

1

2

TYPES OF MATERIAL HANDLED

Ports – Ship Loading & Unloading of Materials

Steel Plants – Ore, Coal, Limestone etc.

Cement Plants – Limestone, gypsum, clinkers etc

Power Plant – Coal

Mines – Excavation, Mining & Handling of Minerals & Materials

Food Industry – Grains ( pneumatic conveying)

CONCEPT OF BULK MATERIAL HANDLING IN PORTS

4

IMPORT OF BULK MATERIAL

Cokeing coal from Australia , Indonesia & Newzeland.

Thermal coal from west Bengal Orissa to south India.

EXPORT OF BULK MATERIAL

Iron ore from Ports like Vishakapattanum , Mangalore, Goa, Paradip , Chennai Etc.

Thermal coal from Ports Like Haldia, Kolkata,Paradip.

CONCEPT OF BULK MATERIAL HANDLING IN PORTS

Receipt of Coal

Unloading

Conveying

Crushing & Screens

Stacking & Reclaiming

Bunkering General ( Auxiliary Systems, Electrical & Instrumentation and Civil

& Structural).

5

SIMPLE FLOW DIAGRAM OF CHP

6

SIMPLE FLOW DIAGRAM OF CHP

TRACK HOPPER

WT 1

WT 2

TP 30

TP 31 TP 32

TP 33

TP 42

TP 41

CRUSHER

TP 47TP 46

TP 45

TP 35

TP 34

TP 44

TP 43

TP 36

TP 37

TP 38

TP 39

TP 40

PH

PH

CONCEPT OF COAL HANDLING

Receipt of Coal

Trucks/dumpers Open Wagons Box N, Box C etc. Bottom discharge wagons Ships Long belt conveyors ( From Ports & Mines)

Unloading

Truck tipplers / Self Unloading dumpers Wagon tipplers / Manual unloading by opening of side doors Track Hopper Ship unloaders / Geared ship / Self unloading ships Surge hopper and feeders

CONCEPT OF COAL HANDLING

Conveying

Feeders (Apron, Vibrating, Belt, Paddle Feeders) Bucket Elevators Steep angle conveyors Troughed Belt conveyors (unidirectional / Reversible) Shuttle Conveyors Pipe Conveyors Chutes & Skirt boards, Hoppers Flap gates, Rod gates, Rack & Pinion gates, Flow dividers, Shuttle heads. Magnetic Separators ( Inline / Cross Belt), Suspended Magnet Belt Weighs Metal Detectors Chute Block Switches Sampling system

CONCEPT OF COAL HANDLING

Crushers

– Ring Granulators

– Double / Four Roll crusher

– Hammer mill

– Rotary Breakers

– Feeder Breakers

Screens

– Vibrating Screens

– Vibrating Grizzly Feeder

– Roller Screen

– Wobbler Screen

– Flip Flop Screen

– Banana Screen

CONCEPT OF COAL HANDLING

Stacking and Reclaiming

Stackers (Single Boom, Twin boom)

Reclaimed (Bucket, Bridge, Bucket on bridge, Barrel, Portal scraper)

Stacker cum Reclaimed (Bucket Wheel)

Undirectioned / Reversible

Bunkering

Motorised Tripper (Single way, Two Way & Three Way)

Bunker Ventilation System

Bunker sealing arrangement

Bunker level monitors (High & Low)

CONCEPT OF COAL HANDLING

General

Dust Extraction system

Dust Suppression system (Dry Plain water, sprinklers)

Ventilation System (Dry, wet)

Tunnel, MCC room

Air conditioning system

Electrical and Mechanical hoists

Service water , Potable water, Pneumatic System

Electric and Instrumentation

Civil & structural

13

REVERSIBLE STACKER CUM RECLAIMER

WAGON TIPPLER & SIDEARM CHARGER

15

PADDLE FEEDER

16

RING GRANULATOR CRUSHER

17

CONVEYING SYSTEM

18

GA OF WAGON TIPPLER COMPLEX

GA OF TRACK HOPPER COMPLEX

COAL PRODUCTION IN INDIA

1900 – 6.12 MT

1920 – 18 MT

1942 – 29 MT

1946 – 30 MT

33 MT – Beg. Of 1St 5 year plan

Now approx. 400 MT/annum

21

UN LOADING FACILITY - CHP

• 1950’s-60’s – Plant 37 MW max emerged

Unloading – Over ground hopper (Truck tippling)

• 1960’s-70’s – Plant of 120 MW max emerged

Unloading – Wagon tippler complex(12-15 Tips/H)

• 1970’s-80’s – Plant of 210 MW max came with pit head concept

Unloading – Through Track hopper, wagon owned by power plant

• Early 90’s Railways started supplying Wagons

Opted to have both Track hopper & Wagon tippler (20 tips/hr)

• After 2000 – Higher Capacity plants started

Wagon tippler (20 – 25 tips/hr) & Track hopper of higher rate emerged

• Recently government is going towards Ultra mega Power plant (4000 MW)

Pit head or Port based unloading

POWER GENERATION IN MAIN STATES

Maharashtra – 14000 MW

Gujarat – 9500 MW

A.P – 8100 MW

Tamil Nadu & U.P - 7000 MW

W.B – 6500 MW

Bihar – 1900 MW

23

CONCEPT OF PORT

Port is basically a Service Provider

Comprises Ship Loader & Un loader Conveyor Stacker, Reclaimer or Stacker cum Reclaimer Wagon Loaders, Flood loading system.

Lower loading & unloading rates leads high penalty Unloading & loading rate is typically higher in ports

GEARED SHIP

MOBILE HOPPER

25

SHIP UNLOADER

26

WAGON LOADER

27

UNIDIRECTIONAL STACKER CUM RECLAIMER

28

29