Ashrant Coal Handling Plant

COAL HANDLING PLANT
Presentation by Ashrant Dass
JINDAL POWER
LIMITED CONSISTING OF 4 UNITS(4X250MW), EACH OF 250MW CAPACITY .

IT
HAS BEEN DECIDED TO BRING COAL FROM NEARBY CAPTIVE MINES BY CONVEYOR SYSTEM. IN CASE OF ANY BREAKDOWN IN THE CONVEYOR SYSTEM , COAL SHALL BE BROUGHT BY DUMPERS & UNLOAD THE SAME IN TOP DUMPER UNLOADING HOOPERS.
ALL EQUIPMENT
OF COAL HANDLING PLANT SHALL BE SUITABLE FOR 24 HOURS A DAY, ROUND THE CLOCK OPERATION.
COAL FLOW DIAGRAM

JPL 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 HOPPER

DUMPER UNLOADING HOPPER RECEIVE COAL FROM OPEN COST COALMINES, TRANSPORTED BY TRUCKS AND WILL BE UNLOADED INTO HOPPER AMONG THREE SIDE AT A TIME. DEVIDED IN TWO SECTION EACH CAPACITY IS AROUND 120 MT.SIX DUMPER CAN BE DUMPED INTO HOPPER AT A TIME.MAXIMUM COAL SIZE 1000 MM. CHAIN FEEDER- 2 NOS A 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 along guides 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 ENGG TYPE: FLIGHT BAR TYPE CF-1/CF-2 CAPACITY: 1000 TPH
ABON SIZER
Low 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 mtph Minimal fines creation Insensitive to clay and sticky materials Pre-scalping of undersize not required Exceptionally low headroom requirements Simple infrastructure requirements due to minimal dynamic loads placed on the supports and structure Ability to start up under a full load Long wear life of consumable components due to positive bite and minimal feed slip. TYPE & SIEZE: LOW SPEED SIZER/6492 X 2884 X 1100 MM MAKE: ABON CAPACITY :1000 TPH MANUFACTURER: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: Capacity: Manufacturer: Supplier:
1017U 1000 TPH. L&T Limited. 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,TAMNAR Industry: POWER Major Equipment: Material Handled: Coal Process: 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 conveyor Direct 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 conveyor PLC 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
Motor-1 Motor-4
Motor-2
Tail drive
Motor-3
Sec drive
Balance Wt
Rope wire
Take-up Trolley Arrgt
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.
Advantage of Pipe conveyor

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
COAL FLOW DIAGRAM CHP INPLANT

DUH Suspended Magnet in Pent House TP 1 CONV 2
CONV 1
Stacker-Reclaimer StockPile TP 3A CONV 5 RBF
CONV 5A TP 4A
StockPile
TP 3
CONV 3A/B
CONV 6 ILMS CONV 4A/B
TP 4
TRAVELLING TRIPPERS ON BUNKER FLOOR
TP 5
INSTRUMENTATION IN CHP
PROTECTION INSTRUMENT
MEASURING INSTRUMENT CONTROL ROOM INSTRUMENT
P R O T E C T IO N IN S T R U M E N T
ZERO SPEED
B E LT SW AY
PULL CHO RD
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 DETECTOR
Type : Electronic Location : On conveyor belt no. 4A & 4B Material 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 UNIT

Location : 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 FEEDER
Type : Electro-Mechanical Location : Under dumper unloading hoppers . Bulk density (volumetric) : 0.8 MT/cu.m Capacity : 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
STACKER-RECLAIMER
MACHINE FEATURES CAPACITY :-1500 TPH (STACKING ) 1500 TPH ( RECLAIMING) MACHINE WEIGHT :- 345 MT BOOM LENGTH :- 41 MTR DRIVE KW :- 8 x 7.5 KW ( LONG TRAVEL) BOOM CONVEYOR KW :- 1 x 110 KW BUCKET WHEEL DRIVE :- 1 x 110 KW SLEW DRIVE :- 2 x 11 KW COUNTER WEIGHT :- 138 MT
INNER BOOM LINK
UPPER MAST
4 nos. of CWT
BOOM LINK SLEW DRIVE GEAR BOX BOOM CONVEYOR MAST STAY TREIPPER STRUCTURE
Bucket Wheel assembled with Buckets & Chute SLEW DECK

SLEW RING BASE FRAME
ELECTRIC GANTRY
Cylinde r
COMPENSATING BEAMS 10-BOGIE WHEEL ASSY 6-BOGIE WHEEL ASSY TRIPPER LEGS
EQUILISING BEAM
TAIL PULLEY
FEED END SKIRT
HEAD PULLEY
GRAVITY TAKE UP
TRANSFER POINT 1 (TP 1)
TP 1- From DUH
TP 1-From TP 3
The 9rd November 2006
COAL HANDLING PLANT

(INSIDE PLANT)
Larsen & Toubro Limited,

Ashrant Coal Handling Plant

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Ashrant Coal Handling Plant

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COAL HANDLING PLANT

Presentation by Ashrant Dass

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

COAL FLOW DIAGRAM

CHP PLANT END

COAL BUNKER PULVERISER

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

DUMPER UNLOADING HOPPER

Model: Capacity: Manufacturer: Supplier:

1017U 1000 TPH. L&T Limited. FFE Minerals, Chennai

BELT CONVEYOR 1200 width (3141 Rmtr.)

TRAVELLING TRIPPER 02 Nos.

STAGES INVOLVING IN CHP

Line Diagram of Cross country Pipe conveyor

Take-up Trolley Arrgt

Concept of Pipe Conveyor

Advantage of Pipe conveyor

COAL FLOW DIAGRAM CHP INPLANT

Stacker-Reclaimer StockPile TP 3A CONV 5 RBF

CONV 6 ILMS CONV 4A/B

TRAVELLING TRIPPERS ON BUNKER FLOOR

CONTROL ROOM INSTRUMENTATION

SYSTEM HARDWARE SPECIFICATION

Harmony cycle time: 0.5 micro second

COAL SAMPLING UNIT

(equipment design) : 1.0 MT/ cu.m

INNER BOOM LINK

Bucket Wheel assembled with Buckets & Chute SLEW DECK

FEED END SKIRT

TRANSFER POINT 1 (TP 1)

The 9rd November 2006

COAL HANDLING PLANT

Larsen & Toubro Limited,

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