Coal Handling and Transportation Systems

1 J une 2010 PMI Revision 00 1
OFF - SI TE FACI LI TI ES
Coal Tr anspor t at i on &
Handl i ng
-As Coal , i s t he pr i me i nput f or a t her mal
pow er pl ant , adequat e emphasi s needs
t o be gi ven f or i t s pr oper handl i ng and
st or age.
-I t i s equal l y i mpor t ant t o have a
sust ai ned f l ow of t hi s f uel t o mai nt ai n
uni nt er r upt ed pow er gener at i on.
-Thi s Pr esent at i on desc r i bes t he ex i st i ng
syst ems of c oal t r anspor t at i on and
handl i ng.
Grade Useful Heat Value
(UHV) (Kcal/Kg)
Corresponding
Ash% + Moisture %
at (60% RH & 40
O
C)
Gross Calorific Value
GCV (Kcal/ Kg) (at 5%
moisture level)
A Exceeding 6200 Not exceeding 19.5 Exceeding 6454
B Exceeding 5600 but not
exceeding 6200
19.6 to 23.8 Exceeding 6049 but
not exceeding 6454
C Exceeding 4940 but not
exceeding 5600
not exceeding. 6049
D Exceeding 4200 but not
exceeding 4940
not Exceeding 5597
E Exceeding 3360 but not
exceeding 4200
not exceeding 5089
F Exceeding 2400 but not
exceeding 3360
not exceeding. 4324
G Exceeding 1300 but not
exceeding 2400
not exceeding 3865
Grades of Coal
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
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.
1 J une 2010 7
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.
Loadi ng
COAL UN LOADI NG
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.
TRACK HOPPER
1 J une 2010 12
COAL-HANDLI NG 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 onlyfor
crushed coal.
COAL HANDLI NG PLANT LAYOUT
Coal Handl i ng
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,
Coal Handl i ng syst em equi pment
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.
Tr ac k hopper t o c r usher
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.
I n t he Cr usher 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.
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
No of hammer in each Crusher-
stage-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
Normal capacity=600 tons/hr
Normally these crushers have a capacity of around 600
tons per hour.
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.
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.
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.
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)
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
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.
Bel t Pr ot ec t i on Equi pment
Pull Chord
Belt Sway
Zero Speed
Chute block
St ac k er c um -r ec l ai mer
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 coal only.
Stacker Reclaimer
St ac k er c um -r ec l ai mer
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-cum-
reclaimer and has a cable reeling drum on which flexible
cable is wrapped.
STACKER-CUM- RECLAI MER
Coal to/from stock yard
Generally 2nos
Capacity ---200T/hr
Maximum---400T/hr
Bucket wheel
Boom conveyor
RECLAIMER IN OPERATION
STACKER IN OPERATION
Bucket wheel
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STACKER RECLAI MER
SEPARATI NG FOREI GN
MATERI AL 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.
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
1 J une 2010 34
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
Winch driven tripper
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.
IMPORTANT FACTORS FOR
STORAGE OF COAL
RANK OF COAL
SURFACE AREA
VENTILLATION
COMPACTION
AGE OF COAL
SIZE AND HEIGHT OF STOCK PILES
%LOSS I NCV SI ZE OF COAL
( MM) 1 YEAR 2 YEAR
50 75 O. 11 0. 24
12 03 0. 5 1. 0
0. 3 0. 2 1. 0 2. 1
PREDICTION OF SPONTANEOUS
COMBUSTION
B-M LIABILITY INDEX:
= 21.48M+ 0.98A- 0.62M
2
-0.58MA+ 0.08A
2
+ 10.2
WHERE, M=% MOISTURE(AIR DRIED BASIS)
A=% ASH(AIR BASIS)
COALS HAVING B-M INDEX > 80 ARE HIGHLY
PRONE TO AUTO-OXIDATION.
MANAGEMENT OF COAL STOCKYARD
Proper coal-air interaction to avoid auto-oxidation and spontaneous
combustion.
Close monitoring during March-J une.
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.
MANAGEMENT OF COAL STOCKYARD (CONTD.)
Stacking in trapezoidal shape, not in conical shape.
Height of stockpile not more than 9-10m (indiancoal).
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.
THANK YOU

Coal Handling and Transportation Systems

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