OFF - SITE FACILITIES Coal Transportation & Handling

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-As Coal, is the prime input for a thermal

power plant, adequate emphasis needs to be given for its proper handling and storage. -It is equally important to have a sustained flow of this fuel to maintain uninterrupted power generation.

-This Presentation describes the existing systems of coal transportation and handling.
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Grades of Coal
Grade Useful Heat Value (UHV) (Kcal/Kg) Corresponding Ash% Gross Calorific Value + Moisture % at GCV (Kcal/ Kg) (at 5% (60% RH & 40O C) moisture level)
Not exceeding 19.5 19.6 to 23.8 Exceeding 6454 Exceeding 6049 but not exceeding 6454

A B

Exceeding 6200 Exceeding 5600 but not exceeding 6200

C
D E F G

Exceeding 4940 but not exceeding 5600

Exceeding 4200 but not exceeding 4940 Exceeding 3360 but not exceeding 4200 Exceeding 2400 but not exceeding 3360 Exceeding 1300 but not exceeding 2400

23.9 to 28.6
28.7 to 34.0 34.1 to 40.0 40.1 to 47.0 47.1 to 55.0
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Exceeding 5597 but not exceeding. 6049

Exceeding 5089 but not Exceeding 5597 Exceeding 4324 but not exceeding 5089 Exceeding 3865 but not exceeding. 4324 Exceeding 3113 but not exceeding 3865
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Daily on an average around 30,000 Tone of Coal is required for a typical 2000 MW Station.
Each super Thermal Power Project has been linked to a particular coal mine to meet its coal requirements The required coal is supplied through Rail wagon. If the power station is away from coal mines then it is fed through Indian Railway system other wise for pit head station it is done through Merry Go Round railway system

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Merry Go Round (MGR) system is a private, full fledged Railway system of NTPC used for hauling the required Coal from Mines to its Thermal power plants. Each coal rake consists of Bottom open Broad Gauge wagons (BOBR) hauled by one/two locomotive.

Modern Multi Aspect Colour Light Signalling (MACLS) system with panel Interlocking is provided for the safety of the rake movement.

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Main feature of MGR Loading System

This system calls for high-speed load- outstation at the mines

It consists of one or two loading silos depending upon the coal requirement of the linked power station The capacity of the silos for the NTPC project varies between 2400 ton/4000 ton. The silos are cylindrical and fed by twin belt conveyors. For accurate weighing of coal to each wagon, Load cells are provided with silos. A sampling unit suitable size coal is provided at the feed point of the loading silo to collect samples for quality analysis The loading operation of the coal rake takes place while it is moving under the silo at a speed of 0.8 k.m. per hr. Wagons are provided with bottom discharge hoppers fitted with pneumatically operated automatic door actuating mechanism. Line side equipment is installed by the track hopper for initiating the opening of doors in groups of 10-14 wagons. The unloading operation of 60 tonne per load wagon takes about 20/30 seconds.
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Loading

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COAL UN LOADING
At NTPC end, Coal is unloaded in the Track hoppers. Track Hopper, normally of 200-250m length. After placing the wagons on the hopper, electrical pulse is given to the pneumatic device for opening the bottom doors. Coal rushes down due to its own weight. When the track hopper is empty, it takes only 20 seconds for unloading one wagon i.e. 60 Tons. This coal falls on a T table, over which a paddle feeder runs and pushes the coal on to a conveyor.

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TRACK HOPPER

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COAL-HANDLING SYSTEM:
Coal handling system is the arrangement for transferring of coal from coal-wagons to coal-bunker or coal stock yard. It also provide arrangement for separation of material impurities, crushing of coals, Coal sampling etc. In the coal handling system of NTPC stations, three coal paths are normally available Path A - direct conveying of coal from track hopper to boiler bunkers. Path B - from track hopper to stockyard Path C - from stockyard to boiler bunkers. The storage facilities at the stockyards have been provided only for crushed coal.
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COAL HANDLING PLANT LAYOUT

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Coal Handling
The coal handling system is designed to provide 100% standby for all the equipment and conveyors. The capacity of the coal handling system for super thermal stations varies from 1200 to 2000 t/h, normally, for a stage of 1000 MW,

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Coal Handling system equipment

plough feeder/ paddle feeder vibrating screen crushers, Conveyor belt, Idlers, Pulleys, Drive Unit, Take-ups, Skirt board, Scrapper, Stacker-cum-reclaimer, Magnetic separators, Motorized tripper. 24 December 2012 PMI Revision 00

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Track hopper to crusher house

Below track hopper paddle feeder arrangement is provided to unload coal to coal conveyors. The 200mm coal as received at the track hopper is fed to the crusher house through 1A & 1B conveyors.

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In the Crusher House

Vibrating Screen :The function of the vibrating screen is: To send the coal having size of less than 20mm to belt feeder through the bypass chute bypassing the crusher and To send the coal of more than 20mm size to the crusher.

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CRUSHERS
To crush the coal from 200mmto 20mm size received from vibrating screen Crusher hammer are made of MAGNEESE STEEL . Hammer row -4(stage 1) (a)Row-1 & 2 =18 hammer each (b)Row-3&4=20 hammers each

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No of hammer in each Crusherstage-1 = 76 hammers stage-2 = 92 hammers Weight of each hammer=18.5kg Crushing motor rating -740kw/3.3kv Life of hammer =4 lac MT of coal PMI Revision 00 Normal capacity=600 tons/hr

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Normally these crushers have a capacity of around 600 tons per 24 December 2012 hour. PMI Revision 00

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CONVEYOR BELTS
Made of diff. Layers or piles of fabric duck with rubber protected by a rubber cover on both sides & edges. Fabric duck are designed to withstand tension created in carrying the load . Nylon rubber cover protect the fabric duck. Material =fire resistant grade. Belt Width=1600 mm. Strength= 1000/1250 kN. Belt speed=3.2-3 m/s. Belt length=20km.

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IDLERS Idlers consists essentially of rolls made out of seamless steel tubes enclosed fully at each end fitted with stationary shaft, antifriction bearing and laybrith sealing. TYPES
TROUGHING IDLERS- shape the belt to support a moving load without spillage or damage to the belt.

IMPACT IDLERS - absorb the shock of falling material at loading and transfer points to protect belt from damage.
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POSITIVE ACTION TROUGHING TRAINERS automatically maintain troughing side alignment in one-way conveyors. A center pivot frame and offset neutral guide rolls provide the troughing action. RETURN IDLERS support the empty belt during the return run.

POSITIVE ACTION RETURN TRAINERS automatically maintain return belt alignment on one-way conveyors.
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PULLEYS

Made of mild steel.

Rubber coating is used to increase friction factor between belt & pulley (rubber lagging

Shell dia-500mm. Shaft dia-1400mm. Pulley length-1800mm. Shaft length-2350mm(bearing centre to centre)
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DRIVE UNIT
Motors coupled to reduction gear with the help of flexible/fluid coupling on the high speed shaft of the Gear box Flexible coupling on the input side

TAKE UPS
Take up pulley to facilitates

Necessary tension for the drive to operate the belt

Sag at a point where requires horse power will be at a minimum and load will move with least disturbance over idlers
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SKIRT BOARD
Used with chutes at trail end. Guides material centrally on the belt while loading until it has settle down on the belt

SCRAPPERS
Placed at discharge pulley in order to clean the carrying side of belt. It avoids the wear of return idlers due to build up material.
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Belt Protection Equipment

Pull Chord Belt Sway Zero Speed Chute block

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Stacker cum -reclaimer

This is used for stacking and reclaiming the coal from stock yard. Generally two stacker claimers have been provided at each of the NTPC's projects. Their normal capacity is 200 tons per hour and maximum design capacity is 450 tons per hour. The stacker reclaimer generally consists of (a) bucket wheel or digging wheel (b) boom conveyor. While the belt conveyor carrying the coal for the stock yard is in the same direction but the direction of the boom conveyor with respect to stacking and reclaiming is opposite. Digging Wheel The digging wheel is use for cutting and lifting the coal from the stock yard to the belt used for transfering coal from the yard. The above transfer takes place in case of reclaiming the 00 coal only. 24 December 2012 PMI Revision 27

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Stacker cum -reclaimer

During stocking operation, the coal from the crusher house is diverted towards the stockyard conveyor at a transfer point TP2/ TP3. The above conveyor discharges coal to the boom conveyor through a discharge chute. The boom conveyor, running in the forward direction, creates coal stacks. During reclaiming, coal from the stock yard falls on the boom conveyor with the help of the bucket wheel and the boom conveyor, during this period, rotates in backward direction. The coal from central chute falls on the conveyor belts used for transferring the coal from the stock yard. By this way, the coal moves on the underground conveyor belts connected to the main belts. A 6.6 KV motor is used for running the stacker-cumreclaimer and has a cable reeling drum on which flexible cable is wrapped. 24 December 2012 PMI Revision 00 29

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STACKER-CUM- RECLAIMER
Coal to/from stock yard Generally 2nos

Capacity ---200T/hr
Maximum---400T/hr
Bucket wheel Boom conveyor
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STACKER RECLAIMER
RECLAIMER IN OPERATION STACKER IN OPERATION
Bucket wheel

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SEPARATING FOREIGN MATERIAL FROM CONVEYOR

MAGNETIC SEPARATOR Any ferrous material on the conveyor will be lifted from the moving conveyor. No Tripping involved. MS is interlocked with Conveyor start up. When ferrous Metal is picked up, the MS is moved from the Conveyor, de-magnatised and the metal piece is removed.
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METAL DETECTOR
Any Metal with an area of 100 Sq Cm will be detected. Conveyor is tripped after detection. MD is not having interlock with start up. A sandbag is dropped near the Metal piece for easy location
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TRIPPERS
To stack material at desired bunker Provided with wheels which moves on rails parallel to conveyor.
Three types motorized tripper Belt propelled manually operated tripper
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Winch driven tripper

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WEATHERING OF COAL
WHEN COAL IS EXPOSED TO ATMOSPHERE - IT REACTS WITH OXYGEN - PRODUCTION OF HEAT - RISE IN TEMPERATURE - OXIDATION REACTION IS ACCELERATED - NUMBER OF CHANGES IN PHYSICAL AND CHEMICAL PROPERTIES OF COAL TAKE PLACE - IT IS CALLED WEATHERING OF COAL.

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IMPORTANT FACTORS FOR STORAGE OF COAL

RANK OF COAL

SURFACE AREA
SI ZE OF COAL ( MM ) 50 75 12 03 0. 3 0. 2 % LOSS I N CV 1 YEAR 2 YEAR O 11 . 0. 24 0. 5 1. 0 1. 0 2. 1

VENTILLATION COMPACTION AGE OF COAL

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SIZE AND HEIGHT OF STOCK PILES

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PREDICTION OF SPONTANEOUS COMBUSTION

B-M LIABILITY INDEX:
= 21.48M+ 0.98A- 0.62M2-0.58MA+ 0.08A2+ 10.2

WHERE, M=% MOISTURE(AIR DRIED BASIS)

A=% ASH(AIR BASIS) COALS HAVING B-M INDEX > 80 ARE HIGHLY PRONE TO AUTO-OXIDATION.
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MANAGEMENT OF COAL STOCKYARD

Proper coal-air interaction to avoid autospontaneous combustion. oxidation and

Close monitoring during march-june.

Design should ensure that for maximum duration of the year, air strikes the width of the stockpile and not the length.

Freshly mined coals should be stacked and old coal should be used.
Freshly mined coals should not be stacked over old coal. Stacking of coal layer by layer, with compaction of each layer.

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MANAGEMENT OF COAL STOCKYARD (CONTD.)

Stacking in trapezoidal shape, not in conical shape. Height of stockpile not more than 9-10m (indian coal). Lumps and fines should be stacked together and compacted. Before stacking coal should be visibly wet.

Segregation of stockpiles into various segments and relevent records of period of stacking, quality of coal (cv) should be maintained.
Compaction of finer particles over the bigger particles.

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THANK YOU

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