COAL HANDLING PLANT

Presentation by Ashrant Dass

JINDAL POWER LIMITED CONSISTING OF 4 JINDAL POWER LIMITED CONSISTING OF 4 UNITS(4X250MW), EACH OF 250MW CAPACITY .UNITS(4X250MW), EACH OF 250MW CAPACITY .

IT HAS BEEN DECIDED TO BRING COAL FROM NEARBY IT HAS BEEN DECIDED TO BRING COAL FROM NEARBY CAPTIVE MINES BY CONVEYOR SYSTEM. IN CASE OF ANY CAPTIVE MINES BY CONVEYOR SYSTEM. IN CASE OF ANY BREAKDOWN IN THE CONVEYOR SYSTEM , COAL SHALL BREAKDOWN IN THE CONVEYOR SYSTEM , COAL SHALL BE BROUGHT BY DUMPERS & UNLOAD THE SAME IN TOP BE BROUGHT BY DUMPERS & UNLOAD THE SAME IN TOP DUMPER UNLOADING HOOPERS.DUMPER UNLOADING HOOPERS.

ALL EQUIPMENT OF COAL HANDLING PLANT SHALL BE ALL EQUIPMENT OF COAL HANDLING PLANT SHALL BE SUITABLE FOR 24 HOURS A DAY, ROUND THE CLOCK SUITABLE FOR 24 HOURS A DAY, ROUND THE CLOCK OPERATION.OPERATION.

COAL FLOW DIAGRAMJPL COAL MINES

CHP MINE END

CROSS COUNTRY CONVEYOR

CHP PLANT END

COAL BUNKER

PULVERISER

BOILER

THE ENTIRE COAL HANDLING SYSTEM DIVIDED IN THREE

SECTION.

1.CHP-1 situated inside plant boundary, capacity 1500 TPH

2. CHP -2 situated mine end, capacity 1000 TPH

3. CHP-3 Cross country conveyor which collect crushed coal

from CHP Mine end at TP-5 and discharge the same at TP-3 of

CHP inside plant, capacity 1500 TPH  

DUMPER UNLOADING HOPPERDUMPER UNLOADING HOPPER RECEIVE COAL FROM OPEN COST COALMINES, TRANSPORTED BY TRUCKS AND WILL BE UNLOADED

INTO HOPPER AMONG THREE SIDE AT A TIME. DEVIDEDIN TWO SECTION EACH CAPACITY IS AROUND 120 MT.SIX DUMPER

CAN BE DUMPED INTOHOPPER AT A TIME.MAXIMUM COAL SIZE 1000 MM.

CHAIN FEEDER- 2 NOSA conveyor comprising one or two endless linked chains with crossbars or flights at intervals to move the coal or mineral. The loaded side of the conveyor runs in a metal trough, while the empty side returns alongguides underneath. The material is transported on the conveyor partly by riding on the chain and flights and partly by being scraped along in the

trough.

MAKE: SWETHA ENGGTYPE: FLIGHT BAR TYPE CF-1/CF-2CAPACITY: 1000 TPH

ABON SIZERLow Speed Sizing Technology is the employment of a combination of high

torque / low roll speeds and tooth profiles to arrive at specified end product sizes with a

minimum of fines production.ADVANTAGE:ROM feed size up to 1500 mm (60”)Capabilities in excess of 10,000 mtphMinimal fines creationInsensitive to clay and sticky materialsPre-scalping of undersize not requiredExceptionally low headroom requirementsSimple infrastructure requirements due to minimal dynamic loads placed on

the supports and structureAbility to start up under a full loadLong wear life of consumable components due to positive bite and minimal

feed slip.TYPE & SIEZE: LOW SPEED SIZER/6492 X 2884 X 1100 MMMAKE: ABONCAPACITY :1000 TPHMANUFACTURER:ABON ENGG

 

COAL CRUSHER Ring granulator crusher having nos. of ring hammers mounted to

rotor disc in a suspension.Due to centrifugal action coal is being crushed between wear plate and hammer and coal sizes is maintained by adjusting the wear plate.

Coal will crushed into two stage, in fist stage coal will crushed 250 mm to 50 mm and in second stage 50 mm to 20 mm.

NOS OF RING GRANULATORTYPE CRUSHER – 04 Nos. Model: 1017U Capacity: 1000 TPH. Manufacturer: L&T Limited. Supplier: FFE Minerals, Chennai

BELT CONVEYOR – 1200 width (3141 Rmtr.)

Belt Conv. – 1A (length): 193 meter. Belt Conv. – 1B(length): 183 met. Belt Conv. – 2A/2B(length): 389 met. x 2 Nos. Belt Conv. – 3A/3B (length): 214 met. X 2 Nos Belt Conv. – 4A(length): 124 met. Belt Conv. – 4B(length): 113 met. Belt Conv. – 5A (length): 226 met. Belt Conv. – 5B (length): 232 met. Belt Conv. – 6A (length): 59 met. Belt Conv. – 6B (length): 65 met. Belt Conv. – 7A (length): 83 met. Belt Conv. – 7B (length): 72 met. Belt Conv. – 2C/2D (length): 117 met x 2 Nos Belt Conv. – 1C (length): 81 met. Belt Conv. – 1D (length): 86 met. Belt Conv. – 1N/1P (length): 92 met.   Belt Conv. – 8 (length): ( 1400 width) 438 mtr

TRAVELLING TRIPPER – 02 Nos.

Type: Motorized Traveling type Capacity: 1000 TPH Travel speed:15 m/min Manufacturer: Domacls Engg. (P) ltd Plant Location: CHP MENE END,TAMNARIndustry: POWERMajor Equipment: Material Handled: CoalProcess:This 1400 wide tripper travels along a belt conveyor and discharges coal into a series of storage bunkers along the path or at the end of the conveyorDirect Bunker Loading: As the tripper moves along the conveyor, a position switch will stop it directly over a bunker. The tripper fills the bunker evenly on both sides until a level indicator inside the bunker tells the tripper the bunker is full. When the bunker is filled, the tripper moves on to the next bunker.Continuous Handling: As the tripper is moving and aligning over the bunkers, it does not stop moving coal on the conveyor. While in transit the tripper feeds coal through its center to a bunker at the end of the belt conveyorPLC Controlled: All movements of the tripper are automatically controlled. However manual control is available. Level indicators signal when the bunkers are empty or full

STAGES INVOLVING IN CHP

Receiving coal at DUH & reclaiming from hopper & feeding in to primary crusher.

Stage wise crushing i.e. primary, secondary, tertiary crushing.

Pre screening & post crusher screening. Coal conveying on TP to next TP to meet process

requirement. magnetic separation, metal detector, on line weighing,

surge hopper, intermittent storage & blending as per process requirement.

Long distance transportation. Feeding in to boiler bunker. storage in stock yard & reclaiming from the stock yard. Yard mgt. like fire fighting , compaction, covering with

tarpaulin, drain network cleaning. CC camera for regular monitoring of plant & equipment.

Line Diagram of Cross country Pipe conveyor

Primary drive

Sec drive

Tail drive

Take-up Trolley Arrgt

Motor-1

Motor-3

Motor-2

Motor-4

Balance Wt

Rope wire

Concept of Pipe Conveyor

Open Type, Troughed Belt conveyor system has been conventional mode of

materials transportation. In the recent years, Pipe conveyor system has

revolutionized the concept by introducing an enclosed materials transfer principle.

The steel cord belt take a shape of a pipe during forward and/ or return run and

flattens itself at the loading and discharge. The idlers are typically arranged in

hexagonal array with 3 roll on one side of module and the balance 3 rolls on the other side.

• Protection of environment against pollution hazards

• Protection of materials against Rain,Dust,Temperature, wind etc

• Elimination of spillage & wastage.

• Reduction of noise emission from conveyor

• Reduction of numbers of conveyor for transporting long distance

• Elimination of theft of coal during transportation.

• Higher carrying capacity compare to conventional conveyor.

• Reduction of numbers of transfer points.

• Lower maintenance and lower manpower

Advantage of Pipe conveyor

DUH

CONV 1TP 1

Suspended Magnet in Pent House

CONV 2

TP 3 CONV 3A/B

TP 4

CONV 5

CONV 6

CONV 5A

Stacker-ReclaimerStockPile

StockPile

TP 3A

TP 4A

TP 5

CONV 4A/B

TRAVELLING TRIPPERS ON BUNKER FLOOR

ILMS

COAL FLOW DIAGRAM – CHP INPLANT

RBF

INSTRUMENTATION IN CHPPROTECTION INSTRUMENTMEASURING INSTRUMENTCONTROL ROOM INSTRUMENT

Z E R O S P E E D B E LT S W A Y P U L L C H O R D

P R O T E C T IO N IN S T R U M E N T

CONTROL ROOM INSTRUMENTATION

PLC based control system shall be configured of 1:1 not redundancy having CPU of word length 32 bits minimum & serial data link interface module for connecting input /output modules,redundant communication processors, memory modules & power supply units.

The power supply shall be derived from single phase , solid state 240V +_1% A.C. UPS with Ni-Cd type battery to provide power to system for at least 30 minutes in case of power black out.

SYSTEM HARDWARE SPECIFICATION

Type : Enclosed self supporting.

Enclosure class: IP-42 Card mounting: 21” rack Harmony cycle time: 0.5 micro

second I/o port: DMA , Program

control

METAL DETECTORType : ElectronicLocation : On conveyor belt no. 4A & 4BMaterial handled by belt: Crushed coal of (-) 20 mm size.Bulk density : 800 kg /cu.m for volume calculation & 1000

kg /cu.m for weigh calculation .Conveyor capacity : 1500 MTPH (Rated & Design)Purpose of installation : To protect Coal mill.

COAL SAMPLING UNITLocation : Transfer point –5.Quantity : 1 set.Type : Automatic two stage.Material handled : Crushed coal.Material temp. : 50 degree c max.& 5 degree min.Conveyor capacity: 1500 MTPH.Belt width : 1400 mm.Belt speed : 3.0 m/s

VIBRATING FEEDERType : Electro-MechanicalLocation : Under dumper unloading hoppers .Bulk density (volumetric) : 0.8 MT/cu.mCapacity : 0-500 MTPH (equipment design) : 1.0 MT/ cu.m

INLINE MAGNETIC SEPARATOR – 3 Nos Type: Electro Magnet, Inline arrangement. Make: Power Build limited mounted on Bc-3A ,3B, BC8 SUSPENDED MAGNET – 02 No. Model: SMNR- 135/ 50 OA, SM 1 and SM-2 Manufacturer: Power Build limited

VIBRATING SCREEN – 02 No, Type- Spring mounted, Capacity- 500TPH, mounted at screen house

 METAL DETECTOR – 02 Nos. Make: Type: Electronic coil Manufacturer: Electromag Device PVT. Ltd

MACHINE FEATURES CAPACITY :-1500 TPH – (STACKING ) 1500 TPH – ( RECLAIMING) MACHINE WEIGHT :- 345 MTBOOM LENGTH :- 41 MTRDRIVE KW :- 8 x 7.5 KW ( LONG TRAVEL)BOOM CONVEYOR KW :- 1 x 110 KWBUCKET WHEEL DRIVE :- 1 x 110 KWSLEW DRIVE :- 2 x 11 KW COUNTER WEIGHT :- 138 MT

STACKER-RECLAIMER

Erection sequence of Stacker - Reclaimer as per enclosed annexure

Top of rail, EL(+)0416

EQUILISING BEAM

TRIPPER LEGS

ELECTRIC GANTRY

TREIPPER STRUCTURE

MAST STAY

UPPER MAST

INNER BOOM LINK

SLEW DECK

SLEW RING

BASE FRAME

COMPENSATING BEAMS

10-BOGIE WHEEL ASSY

6-BOGIE WHEEL ASSY

BOOM LINK

BOOM CONVEYOR

SLEW DRIVE GEAR BOX

Cylinder

4 nos. of CWT

Bucket Wheel

assembled with Buckets

& Chute

TAIL PULLEY FEED END SKIRT

HEAD PULLEY GRAVITY TAKE UP

TRANSFER POINT 1 (TP 1)

TP 1- From DUH

TP 1-From TP 3

COAL HANDLING

PLANT (INSIDE PLANT)

Larsen & Toubro Limited,

ECC Division

The 9rd November 2006