coal handling
TRANSCRIPT
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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.
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.
Grade C.V. ( K Cal / Kg. )
% Ash + Moisture
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
F 2401-3360 40.14 - 47.10
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TRANSPORTATION OF COAL5 ways of Transportation.
• 1. Railways.• 2. Ropeways.• 3. Roadways.• 4. waterways.• 5. Airway.
Available only for TPS nearer to coal
mines
Have to build Runway near TPS which is very
costly.
waterway may not be possible till TPS and
Problem of recalling arises if coal dip in water
Best and Cheap facility at Doorstep
Fear of thief
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BY RAIL WAY 80-90% of the requirement is fulfilled by this way.
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.
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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
Wagon Tippler Crusher House
Bunkers
Tripper Trolley
Conv. Belts Vibrating Screens
Crushers
Feeder Surge Hopper
Hopper
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Operational Cycle
Wagon Tippler
Conveyer Belt System
Crushing Mechanism In CHP
CHP Auxiliaries
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BUNKERING CYCLE
Bunkers
From W/T
Bunkering Belts
Surge Hopper
Vibrating Feeder
Crusher House
Crusher
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STACKING CYCLE
Bunkers
Stacking Belts
Crushed Yard
From W/TCrusher House
Bunkering Belts
By-Passed Coal
Coal Is not required if bunker is full or Due
any maintenance
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RECLAIMING CYCLE
Bunkers
Reclaiming Belts
Crushed Yard
Non-Crushed Yard
From W/TCrusher House
Bunkering Belts
If Outer Supply of coal Is Not Present
Stacked Coal
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WAGON TIPPLER These are used to unload the coal wagons into coal
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
Mesh of 250 mm * 250 mm
Hopper
Vibrating Feeder
Conveyor Belt
To crusher House
GENERAL LAYOUT OF W/T
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CONVEYOR BELT SYSTEM
Construction of Conveyor Belt Conveyor Belt Drive System Counter Weight Idlers Protection System
Interlocking Magnetic Separator
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CONSTRUCTION OF CONVEYOR BELT
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.
Net
Strength = 600 N
1000 mm
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CONVEYOR BELT DRIVE SYSTEM
Motor G / B
Fluid CouplingFilled with 3/4th oil
Fusible plug
Head End Pulley
Tail End Pulley
oSpeed before crusher 2.4 m/secoSpeed After Crusher 2.7 m/sec
Belt Speed
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COUNTER WEIGHT
Return Idlers
Idlers
Counter Weight
Head End Pulley
Tail End Pulley
Conveyor Belt
RailingTake-up Pulley
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IDLERS
Carry Side Return Side
Self Alignment Impact Return Roller Return Adjustment Roller
( Installed after every 25m )
Below Discharge chute( rubber coating )
35°
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ANGLE OF IDLERS
Angle Merits Demerits
20° No middle idler is overloaded
More Coal Derailed
35° Coal not Derail. Middle idler is overloaded
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PROTECTION SYSTEM
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 CrusherW / T No.4
DRCR RBCR Impact250 mm
80 mm
600 mm
20-25 mm
Stage 1 Stage 2
Stage 3
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ROTARY BREAKER CRUSHER ( RBCR )
Striking Plate
Hole of diameter 100 mm
250 mm
80 mm
Stone shell