Design & engineering of

COAL HANDLING PLANT

at
HEADS OF CHP MEET

By
VINAY KUMAR
 Points of Discussion
1.0 CHP-LAYOUT
2.0 SYSTEM DESCRIPTION
A. UNLOADING
B. CONVEYING
C. CRUSHING
D. BUNKERING
E. STOCK YARD MANAGEMENT
F. AUXILIARY & SERVICE FACILITIES
3.0 DESIGN ASPECTS
4.0 DESIGN MARGINS
 COAL FLOW PATH

UNLOADING CONVEYING CRUSHING

CONVEYING
STACKING
STOCK
PILE RECLAIMING
TPs

BUNKERING
 TYPICAL CHP LAYOUT

MAIN PLANT
CRUSHER HOUSE
MILLS

UNLOADING
AREA

STACKER RECLAIMER
S

Ideal Layout for CHP should be with minimum Flow path

MAJOR CONSIDERATIONS

SHAPE OF LAND --
STRIP/SQUARE/RECTANGULAR

WIND DIRECTION

MINIMUM DISTANCE FROM BOILER

BUNKERS/
COAL STOCKYARD

FUTURE EXPANSION

Factors effecting
• Availability of land and its shape
• Interconnection with existing stages
• Railway siding layout
 DESIGN BASIS

 Lump size 250mm, 1-2% 400mm

 HGI 44-65
 Moisture 12-15% , 20% for design purpose
 shale and sand stone as high as 20%.
 Bulk density 800Kg/m3 for volumetric
calculation
 Bulk density 1100Kg/m3 for load calculation
 CHP CAPACITY FOR : 2 x 660 MW PLANT
 UNIT HEAT RATE = 2447 KCAL/KWHR
 COAL CALORIFIC VALUE = 3300 KCAL/KG
 (DESIGN COAL)
 SPECIFIC FUEL CONSUMPTION = 2447/3300
 = 0.7415 KG/KWHR
 HOURLY COAL CONSUMPTION BY
 2X660 MW UNITS = 0.7415X2X660X103
 1000
 = 978. 8 Te
 DAILY COAL REQUIREMENT = 978.8 X 24
 = 23,481.2 Te
 RATED CAPACITY = DAILY COAL REQUIREMENT *1.1/12
 = 23481.2*1.1/12 = 2153.36 MTPH = 2200 MTPH
 SIZING OF COAL HANDLING PLANT

1. 100% PLF with design coal at BMCR.

2. Peak daily requirements shall be met by two shift operation with 12
hrs net operating hours of CHP.
3. 10% margin on daily coal requirements to calculate rated capacity.
4. Station heat rate:
500mw: 2500kcal/kwhr
660MW/ 800MW: 2250 kcal/kwhr
5. Design capacity-110% of rated capacity
6. 2x100% conveying stream
7. Design Margin for Equipment
Crushers 10%
Paddle feeders 50%
Vibrating feeders 10%
Sl no Equipment Duty Design margin as
requirement %age of duty
requirement

1. crushers 2x50% 110%

2. Vibrating screening 2x50% 110%

feeders

3. Paddle feeders 2x50% 150%

4. Stacker-reclaimer 1X100% 10% for stacking &
125% for reclaiming
 SIZING OF COAL HANDLING PLANT …contd

Conveyors
* 2 x100% capacity - double conveyor streams
Equipment
* Two (2) crushers & two (2) grizzly feeders
are dedicated to each incoming conveyor in crusher house
* Two (2) nos paddle feeders operated on each conveyor in
the TH.
 UNLOADING TERMINAL

1. Track Hopper

Type of wagon to be unloaded: BOBR wagon

Storage capacity of hopper: 1.5rakes

- Length of Track Hopper: 330m including 15m of each M/c bay

( may vary based of layout)

- Depth of Track Hopper : 10.5m or 12 m to achieve storage

capacity based on length
- Valley angle of hopper : not less than 60o

- 50 thk gunniiting is provided at complete inside surface of hopper

and surface of beam inside hopper for easy flow ability of material
 PADDLE FEEDER
Quantity: Two nos. for each stream
Design capacity: 150% of rated capacity
 UNLOADING SYSTEM
2. INDIAN RAIL WAY WITH BOX N WAGON
- Wagon tippler- Side discharge & Rotary
- Side arm charger
- Apron feeder

Hopper capacity- 250te

- Appron feeder- 2200TPH

(based on DFC25 )
 MAJOR CHANGES IN REVISED GUIDELINE G-33

Parameter G-33 (ERALIER G-33 LATEST

REVISION) REVISION
Wagon Design 25 Tons 25 Tons & 32.5 Tons

Wagon tippler Design 110 Tons with an axle 140 Tons with an axle
Gross Load load of 25 Tons load of 32.5 Tons

Tippling Time Cycle Rated : 20 tips / hr 25 Tips / hr

Design : 24 Tips / hr

Type of Wagons BOX / BOX - N BOX-N/BOX-N 25/

DFC-25 & DFC-32.5

Side supporting beam Stationary Movable Hydraulic

operated
 WAGON TIPPLER

LATEST DEVELOPMENT AS PER REVISED RDSO GUIDELINES:

TYPE OF WAGON NO. OF Width REQUIRED

WAGON CAPACITY TIPS/HR (mm) CONV./APPRON
(Te) FEEDER CAPACITY

BOX-N 60 25 3250 1500

BOX-N 25 77 25 3125 1925

DFC 25 82 25 3500 2050

DFC 32.5 108 20 3660 2160

 CONVEYING

 BELT CONVEYOR
 PULLEY
 IDLER
 DRIVE
 SAFETY SWITCHES
 BELT CLEANER
 MD & SM & ILMS
 CHUTE
 BELT CONVEYOR

STEEL CORD/NYLON/EP BELT FR GRADE 1200 – 2000 MM WIDTH

PULL CORD SWITCH SPACING 30 M
BELT SWAY 50 M
ZERO SPEED BEND PULLEY OF GTU
 SELECTION OF BELT

1. Selection of Belt width

 Conveyor capacity
 Belt speed- type of material, belt width (3.4m/s max.)
 Troughing angle-35o
 Fill factor-80-90%
 Slope factor: 0.89
 Maximum lump size is 1/3rd of belt width with 10% lump and 90%
fine
2. Selection of Belt Rating
 Maximum tension
 Width of belt
 Loading factor : 80%
 Factor of safety- 10 for N-N belt and 7 for steel cord
 IDLERS

152 MM DIA x 4 MM THICK TUBE ROLLS WITH LIFE SEALED , DEEP-

GROOVE BALL BEARING, SEIZE-RESISTANT
SPACING - CARRYING IDLER 1.2M
SPACING - RETURN IDLER 3.0M
CONVEYING SYSTEM
 SAC IDLER
SPACING-15M & 10M FROM
HEAD & TAIL PULLEY
 RETURN IDLER
- SINGLE ROLL FLAT IDLER
- TWO ROLL V –TYPE (10O)
FOR BELT WITH MORE THAN 400M LONG.
- SPACING-3M & 1.5M AT
CONVEX CURVE
 BELT CLEANING IDLER
 SAR IDLER
 MACHINED IDLER
2. IDLER.
CONVEYING
 CARRYING IDLER
- THREE EQUAL ROLL
- ROLL DIA-152.4MM
- SPINDLE DIA- 35MM (2000TPH & ABOVE)
- 30MM( BELOW 2000TPH)
- SHELL THICKNESS- 4MM(MIN.)
- SPACING -1200MM & 600MM AT CONVEX ZONE
- TROUGHING ANGLE-35O
 IMPACT IDLER
- MIN. 6NOS. AT EACH
LOADING POINT
- SPACING -400MM
- ROLL DIA- 190
- SHELL DIA-139
 PULLEY

RUBBER LAGGED - 12 MM THICKNESS - HERRINGBONE/DIAMOND

PATTERN FOR DRIVE PULLEYS; PLAIN FOR NON-DRIVE PULLEYS
 PULLEY
(iii) SIZES OF PULLEY
- DIA- AS PER BELT MANUFACTURER
RECOMENDATION but min as follows
a. DRIVE PULLEY-800MM
FOR HIGHER BELT RATING
PARTICULARLY FOR STEEL CORD BELT-1000mm
b. OTHER PULLEY-630MM
- PULLEY FACE WIDTH- As per IS 8531
- SHAFT SIZE, SHELL & DIAPHRAGM THICNESS
IS CALCULATED BASED ON LOAD ACTING ON
PULLEY
 CERAMIC LAGGING OF PULLEY

It gives the highest co-efficient of Friction ( 0.6 )

in Lagging under wet, dry or muddy condition.
DRIVE EQUIPEMENT
Motor
20% margin on consumed power at design capacity
High Speed Coupling
a. Traction type fluid coupling for LT motor
b. Scoop type fluid coupling for HT motor

Gear Box- bevel helical/ helical type

Low Speed Coupling – geared coupling.

Chute & Flap Gate
1. Chute width- 2/3 of belt width
2. Valley Angle- 60o min.
3. Chute profile
- Chute must be inclined in the direction of belt movement
- Central feeding on belt
4. Material of chute- 20 Thk. TISCRAL at sliding face & 10 thk. at non
sliding face. Flap gate zone and chute where valley angle is more
than 80o 20 thk. TISCRAL
6. Flap Gate:
actuator torque: 3500kg-m for 2000TPH and above
2500kg-m for below 2000TPH
Material of gate: TISCRAL/SAILHARD
SKIRT BOARD
1. Length
Extended min.3m ahead of
front edge of chute
500mm behind rear edge of
chute
2. Height- 750mm
3. Hidth- 2/3 of belt width.
 SAFETY SWITCHES

1. Pull Cord
- At every 30m interval of conveyor
2. Zero Speed
- Mounted on bend pulley
3. Belt Sway Switch
- One pair at every 50m interval
4. Chute Blockage Switch
Magnetic Separators
ILMS/CBMS/Magnetic pulleys/Suspended magnets

-To pick MS cube 20 mm, brake shoe 15 kg, MS plate of 250 x 250x 100
size, shovel teeth and spikes
-1000 gauss strength. 450/400 mm mounting height for ROM/crushed
coal

Metal Detector
LED display for coast count/total count
sand bag marker
Detect 25 mm Aluminium sphere below coal burden for synthetic belt &
35mm for Steel cord belt
 BELT CLEANER

- EXTERNAL BELT CLEANER

- INTERNAL BELT CLEANER
 CRUSHING SYSTEM
VIBRATING SCREEN FEEDER
- Under size to bypass crusher
- Uniform feed over crusher inlet
 Screen area: Min. 0.75 sq. m per 100TPH feed
 Perforation : Suitable to pass (-) 20mm coal
 VIBRATING GRIZZLY FEEDER

- 20 MM 2000 TPH BELOW CRUSHERS

 CRUSHER

- Crushing to (-)20mm
size
- Duty requirement-
2x50% or 1x100% per
conveyor for
smaller capacity
- Toothed hammers
for crushing (ring
granulator)
BUNKERING

 TRAVELLING TRIPPER- TO FILL BUNKERS

1. TWO WAY CHUTE

2. THREE WAY CHUTE

CAPACITY OF TRIPPER : CONVEYOR CAPACITY

TRAVELLING TRIPPER
 STACKING SYSTEM
1. 1. Unidirectional Stacker Reclaimer
2. 2. Reversible Stacker-Reclaimer
Basic feature: Traveling, Bucket Wheel type, Slewable, luffable
Boom Length: 41m for 50 m wide pile base
 Ratio of Boom Length to Track Centre distance not to exceed
5:1.
 Bucket discharges per minute should not exceed 55 to limit wear.

Stock Yard management

Crushed coal (-)20mm size coal is stacked
Height of stock pile 10m max.

Approx. coal stock required (based on land availability):

Pit head : 15days coal requirements
Load centre : 30 days coal requirements
Coastal :45days
 STACKER RECLAIMER

MAST

BUCKET
COUNTER
WEIGHT
BOOM

SLEWING RING
BOGIE

RAILS
R
A
I
BUCKET TYPE 3200 TPH 41 M BOOM
L
DUST CONTROL METHODS
1. Dust suppression system
2. Dust extraction system
Location wise Dust Control Methods
are as follows
i) Track Hopper top - Plain water DS
(2 lpm, 2.5ksc), WT-Plain water DS (2lpm, 4.5KSC)
ii) conveyors & TPs/CH – dry fog ds (0.5 KSC water, 5 KSC air)
iii) Crusher House - DE
- Grizzly floor
- Belt feeder floor
iv) Stockyard - Plain water DS (500lpm, 4.5KSC)
v) Bunker Bay - Sealing Belt
Typical Scheme of Dry Fog system