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INDEX

SLNO DESCRIPTION
PART- I (GENERAL DESCRIPTION OF SYSTEM)
1.0
1.1
1.2

DESIGN BASIS AND WRITE UP


TECHNICAL SPECIFICATION OF EQUIPMENT/ACCESSORIES

2.0

PART- II (FOR SECONDARY CRUSHER HOUSE#SCHN-1 ) : (DE-1)

2.1
2.2
2.3
3.0
3.1
3.2
3.3

CAPACITY CALCULATION
PRESSURE DROP CALCULATIONS
SCHEMATIC DIAGRAM

ANNEXURE - I
ANNEXURE - II
ANNEXURE - III

PART- III (FOR CRUSHER HOUSE#CRHF-1 ) : (DE-2)


CAPACITY CALCULATION
PRESSURE DROP CALCULATIONS
SCHEMATIC DIAGRAM

ANNEXURE - IV
ANNEXURE - V
ANNEXURE VI

DESIGN BASIS REPORT


FOR
DUST EXTRACTION SYSTEM

PART I

SYSTEM SUMMARY
SL
NO.

SYSTEM
NO.

DE-1

DE-2

LOACTION/
BUILDING
SECONDARY
CRUSHER HOUSE
#SCHN-1
CRUSHER HOUSE
# CRHF-1

NO
OF
FAN
S

MOT
OR
KW

Compres
sor with
air
receiver

CAPACI
TY

TOTAL
Pr.

47000
m/hr

330
mmwc

75

47000
m/hr

330
mmwc

75

LOCATION OF DE POINTS
SL
NO.
1
2
3

BUILDING

SECONDARY
CRUSHER
HOUSE #
SCHN-1

NO OF
POINTS
WORKIN
G

EQUIPMENT

POINTS

TOTAL
POINT
S

GRIZZLY
FEEDER

VGFN-1A/ VGFN1B

CRUSHER
CONVEYOR
BCN-3

CRN-1A/CRN-1B

LOCATION OF DE POINTS
SL
NO.
1
2
3

BUILDING

CRUSHER
HOUSE
#CRHF-1

EQUIPMENT

POINTS

TOTA
L
POIN
TS

GRIZZLY
FEEDER

VGFF-1A/ VGFF1B

CRUSHER
CONVEYOR
BCF-2

CRF-1A/CRN-1B

NO OF
POINTS
WORKING

(GENERAL DESCRIPTION OF SYSTEM)


1. DESIGN BASIS AND WRITEUP FOR DRY TYPE DUST EXTRACTION SYSTEM
Dust Extraction system is provided at Crusher House, to extract coal dust laden air from
vibrating screens, Crusher and receiving points on Conveyor from screens and crushers, clean
the dusty air through Dry type Dust Extraction system & let the cleaned air to atmosphere
through ID fan and stack.
In this system incoming conveyor no. BCN-2/BCF-1 discharges coal to either vibrating screen
VSFN-1A/VGFF-1A and crusher CRN-1A/CRF-1A or vibrating screen VSFN-1B/VGFF-1B and
crusher CRN-1B/CRF-1B simultaneously. From screens, oversized material is fed to crushers,
undersized material from screens and crushed material from crusher is fed to Conveyor BCN3/BCF-2.
Suction hoods are provided at Screens, Crusher and on the skirt boards of receiving conveyor.
Ducting shall collect dust from various points of discharge and receiving points of conveyors.
The collected dust form the bag filter shall be discharged to outgoing conveyor.
The Dust Extraction type dust control system to be furnished under this specification is required
for controlling fugitive dust emissions from dust generation points such as secondary crusher
house #SCHN-1 and crusher house CRHF-1.Bag filter type dust extraction (DE) system shall be
provided for the proposed area. DE system shall be provided with Centrifugal Fan, Bag Filter
Unit, Dampers (Motorized Dampers if required), Dust Extraction Hood, Duct work with support,
Rotary Air Lock Feeder, Air Compressor with accessories & control components and panels.
Protection against fire/explosion shall be provided.
All equipments & components shall be designed & selected considering ambient temperature of
50deg. C (Max.) & 4 deg. C (Min.)
As per specification D.E System has been designed considering single stream operation.
1.1. Dust Extraction system has been considered for the following areas:
1.1. A Dust Extraction system (Bag Filter)
A) Secondary Crusher House # SCHN-1
B) Crusher House # CRHF-1

:
:

(DE-1)
(DE-2)

1.1.B DE system (Dry Type Extraction Bag Filter)


System (Part A)
Dust Extraction system has been designed in accordance with "American Conference for
Governmental Industrial & Hygienists" (ACGIH). Capacity of DE system has been calculated as
per ACGIH recommendations for each system above.
Calculations for the total air quantity, sizes of ducts & fans, pressure drop in the ducting,
equipment & air outlets etc., are done independently, based on conveyor belt speed, width, sizes
of various equipment involved and for selecting suitable dust extraction units. The minimum

extraction quantity at various dust extraction points shall be as per values given in the table
below and wherever it is not specified; the same has been considered based on "American
Conference of Governmental Industrial Hygienists" (ACGIH) recommendation.
1.1.C Amount of air to be extracted:
At the conveyor
discharge pulley

2800 m3/hr/m of belt width above speed of 1.0 m/s

At the loading point of


2800 m3/hr/m of belt width above speed of 1.0 m/s
conveyor on the skirt board (for 1 m fall of material)
In case material fall is more than 0.92 m, 1700
m3/hr is added, as additional air quantity required.
Screen Inlet

Min 915 m3/hr/m2 area of screen

Crusher Inlet

3600 m3/hr/m width of inlet opening

DE system shall be of outdoor type. However necessary weather protection cover/hood shall be
provided for the motors, control system for the bag filter cleaning etc.
The following parameters shall be considered for designing DE system:
a) The dust concentration at the extraction point to be considered for selection of bag filter shall
be 10 g/m3 (minimum).
b) Manual dampers fusible link type in the individual suction hood is provided.
c) The DE fans shall have straight but backwardly inclined blades.
d) The bag filter material shall be fire proof/retardant, non-woven type, polyester needle felt
mounted on cages of GI, with antistatic property. Pressure drop of the bag filter shall be
limited to 100 mmwC.
Fan static pressure shall meet the total system frictional loss in the system.
e) The air to cloth ratio of the bag filter shall not exceed 1.5 m3/min/m2. The fabric weight shall
be min. 550gm./m2.The bag filter cleaning system shall be automatic on line reverse pulse jet
compressed air system.
Necessary compressors, piping, valves, timers, etc. shall be provided as per system
requirement.
f) Dust factor of 1.5 shall be considered for crushed coal/fines at receiving point as per ACGIH
recommendation.
g) Thickness of suction hood shall be minimum 5mm.Thickness of ducting shall be min. 3.15 mm
and 5 mm at the bends. Thickness of casing of centrifugal fan shall be minimum 5mm.

h) DE system shall be operated (started/stopped) from the local control panels as well as main control
room and interlocked with operation of conveyor equipment.
i) Design philosophy for duct sizing and fan selection is based on "Balancing without blast gate"
method as per ACGIH hand book. Duct shall be sized based on a velocity of 18 to 21 m/s.
j) Discharge of exhaust air to atmosphere is through chimney with cowl at a height of 3m above the
top of building.
k) No suction hood shall be provided at discharge of conv.# BCN-2 and BCF-1 as ILMS is located on
the top of discharge hood. It is difficult to place suction hood at discharge point of the above
conveyor. This is standard practice. Hence no suction' hood has been considered due to non
feasibility of providing cut out for suction hood at discharge point.
q) Dust emission level shall be limited to less than 30 mg/Nm3 at stack outlet.
Bag filter, fan and other accessories will be installed on the ground/roof of the Crusher house. Dust
collected from bag filter shall be discharged into the respective conveyor through rotary air lock
valve. Compressed air with required pressure and quantity, for cleaning of bags of bag filters shall be
provided separately for each DE-system.

Compressed air requirement


The compressed air required for the system is as follows: DE-1 40 CFM
DE-2 40 CFM.
The requirement of the compressed air will be catered by tank mounted non-lubricated piston
compressor; one each for DE-1 and DE-2, with accessories viz. filter unit, moisture eliminator
etc shall be provided.

1.2. TECHNICAL SPECIFICATION OF EQUIPMENT/ACCESSORIES


1.2.1. BAG FILTER
Pulse Jet Type bag Filter Unit having an efficiency of 99.9% down to 5 microns shall be
provided. It shall be complete with supports, maintenance walkway, platform with hand railing
and cage ladder etc for access to bags & solenoid valve etc. Sheet metal rain protection hood /
canopy shall be provided above bag filter unit, and also for drive unit components / motors of fan
/ airlock feeder etc.
Bag dust collector units shall consist of bag filters of hose like structure contained within a sheet
metal chamber, dust collecting hopper, discharge chute with rotary air lock feeder. Each unit
shall include suitably stiffened filter housing of sheet steel, gas inlet, gas distribution
arrangement, filter bags secured to the housing by clamps, exhaust chamber, supports to provide
a minimum clearance of 1.5 M from floor level (unless otherwise specified), differential pressure
gauge/DP switches to measure the pressure drop across the units etc.The casing of bag dust
collector shall be fabricated from 5 mm thick M.S. plate. Dust control hopper to be made out of
5mm thk. SS-409M .Bag filter shall be high ratio type with pulse jet bag cleaning arrangement.
Pulse jet type cleaning arrangement shall consist of a header for compressed air supply and
distribution piping and electrically operated diaphragm type solenoid valve with timer.
A solenoid valve will serve each row of bags and each bag shall have a well-designed venturi.
Filter bags shall be secured to the housing by clamps. The bags shall be manufactured of suitable
material, e.g. synthetic fabric of type/ trade names such as poly propylene, polyester nylon,
teryline, nomex, Teflon, glass fiber etc. fireproof, non-woven type with antistatic properties. The
pressure drop shall be limited to 100 mm WC. The air to cloth ratio of bags/filters shall not
exceed 1.5 Cu. M per min. per Sq. m. The bag housing shall have platform with hand railing &
cage ladder to have access for attending the bags and solenoid valve for maintenance purpose.
The bags shall preferably be grouped in separate compartments to facilitate bag cleaning. The
collector shall have airtight access doors into bag compartment and hopper.
DP Switch for alarm annunciation/cleaning mode operation shall be provided. Gauge & pressure
switch shall be provided in the compressed air pipe.
Dust feeding arrangement back to return conveyor belt shall be through rotary air lock valves.
Dust concentration at outlet/stack shall be restricted to 30 mg/Nm3.
1.2.2. CENTRIFUGAL FAN & ACCESSORIES
Centrifugal fan shall be single inlet, single width type with flat backward inclined blades. As the
dust concentration at the outlet of bag filters shall be low, backward curved bladed fans with high
efficiency may be considered if blade erosion is not anticipated. Fan shall be sized equal to 1.15
times the total dust collection system airflow rate .
The fan shall be of type SWSI. The fans shall be of robust construction and shall be of outdoor
type. The casing and impeller shall be manufactured of sheets thicker than the thickness used for
normal ventilation fans, so that the fans may handle coal dust laden air. Design duty point of the
fans shall match with the average value maximum and minimum flow rate of the fan in the stable
operation zone. Operating speed of the centrifugal fan shall not be more than 1500 rpm and
velocity at outlet shall not exceed 20 m/sec.
The fans shall be capable of withstanding the stresses which may be experienced during normal

Operation and during over speed testing. All fans shall be suitable for outdoor operation.
All fans shall preferably be designed to operate between 10% and 130% of system throttling line.
All the fan units shall be reasonably noise and vibration free in operation and hence of
reasonably low speed. The noise level shall be limited to 85 db at 1-meter radius.
The casing shall be of welded construction fabricated with 5Thk MS plate. It shall be rigidly
reinforced and supported by structural angles. The seams shall be permanently sealed airtight.
Split casing shall be provided on larger sizes of fans. Casing for centrifugal fan shall be
reasonably leak proof. The casing shall be provided with inspection door, lifting lugs, and drain
with drain valves wherever required.
The fan shall be suitable for belt driven electric motor. Belt shall be sized considering minimum
service factor of 1.5 times & there shall be min 2 belt/drive the fan & motor shall be suitable for
continuous operation.
The motor specification shall conform as per approved data sheets. The starting torque
characteristic of the motor shall be suitable for the duty desired. The motor shall be rated for
continuous operation. However, motor rating shall not be less than the max. Power demand
throughout the entire range of operation of fan.
Drive motor HP rating (Min.) = 1.2 x (BHP of Driven equipment + drive loss
Fan is always operated with inlet damper in fully open condition.
For design purpose, outdoor ambient temperature shall be taken as 50 deg. C (Max.)& 4 deg.C
(Min.). However fan shall be selected for operating at minimum temperature as well as the
maximum temperature (with minimum static head as indicated in the DBR) as indicated in
general conditions of supply.
All centrifugal fans shall have adequate arrangement for vibration isolation of minimum 95%
efficiency.
The first critical speed of all fans shall be at least 25% above the rated speed.
All fan mountings shall have adequate arrangement for vibration isolation (kushy foot).
Design duty point of the fans shall match with the average value of maximum and minimum
flow rate of the fan in the stable operation zone.
The entire Fan shall be supplied with inlet & outlet flexible connection, common base frame for
fan & motor, sheet metal canopy for motor, foundation bolts for fan, pulley, v-belt, belt guard
and other accessories.
All centrifugal fan shall be complete with electric motor drive, impeller, casing, supporting
structure, pair of slide rails for motor and common base frame with foundation bolts ,drive
pulley,V-belts,belt guard ,vibrationisolators,dampers and flexible connection with matching
flanges, sheet metal canopy over motor, butterfly damper at fan inlet, fan discharge side ducting
with exhaust cowl and bird screen. The exhaust air after filter shall be discharged at the height of
3m above roof level of building /structure.
1.2.A. MATERIAL OF CONSTRUCTION OF CENTRIFUGAL FAN & ACCESSORIES
Type
Blade Type
Gas composition

: SWSI
: Backward (min 5mm thick) with self cleaning.
: Air laden with coal dust for DE system

Construction
Impeller
Fan Shaft
Fan Scrawl
Case
Supports, frames, structure
Damper
Flexible connection at inlet
& outlet
V Pulleys
V-Belts

: V -belt driven.
: FE410W (IS: 2062)
: EN-8
: Heavy gauge MS (IS: 2062)
: MS (5mm thick minimum)
: MS of adequate thickness
: Heavy gauge MS (IS: 2062), Butterfly type
: Rubber impregnated canvass with MS Flanges
& cleats.
: Multi grooves (IS: 210, FG-20)
: Reinforced rubber of appropriate section. Belts
should be in matched set.(min 2 nos/drive)

Slide rails

:C.I. or MS

Vibration Isolating pad

: Hard synthetic rubber of hardness 40 degree


shore

Bolts & Nuts

: As per IS: 1367.

Accessories required

: Flexible connection at fan outlet, inlet guard, fixed


type inlet vane outlet damper, spring type
vibration isolator with minimum isolation
efficiency of 80%, ribbed neoprene rubber pads
between foundation block and floor, filter, slide
rails belt guard, sheet metal canopy over motor
,bird screen etc shall be provided.
: Pulleys shall have minimum 2 grooves. Belts shall
have minimum S.F 1.5. . (Min 2 nos/drive)

1.2.3 DUCTING
The ducts for conveying dusty air shall be of round shape and of streamline appearance.
Based on "Balancing without blast gate" method as per ACGIH hand book, the velocity of air in
the duct shall be high enough (in the range of 18 to 21 m/sec.) to transport the suspended dust in
the air.
Ducting shall be made of MS Sheet of 3.15 mm thickness and 5mm thick for bends. The duct
shall be properly painted.
Duct supports shall be provided as per stipulations hereunder:
Diameter of duct
Less than 200 mm
More than 200 mm

Spacing of support
Maximum 2.5 meter
Maximum 3.0 meter

The ductwork shall be properly reinforced to prevent sagging, buckling and vibration. Interior of
ducts shall be smooth and free from obstruction.
Flexible connections shall be provided at the duct connections to inlet and discharge of the fans.
All flexible connections shall be non-collapsible type and their length shall be kept to a
minimum.
Duct supports, wherever required, shall be provided. Hangers and support positions shall be
made as per good engineering practices.
Medium pressure ducts for dust extraction shall be welded and shall have flanged joints.
Thickness of flanges shall be minimum 5 mm for duct sizes up to and including 500 mm
diameter. For duct sizes above 500 mm diameter, the flange thickness shall be minimum 6
mm.MS flange complete with gasket shall be provided. Type, thk & material of gasket shall be
air tight at flange joints.
Vertical duct passing through floor slab shall be supported by means of collars constructed of
structural steel angles securely fastened about the girth of the duct and resting on the floor slab.
The supporting angle shall be fastened to the floor slab with a filler or bitumastic compound
inserted in between the horizontal leg of the supporting angle and the floor.
All ducts running on the floor / roof shall be adequately fixed in position by MS
Angles/channels.non collapsible connection shall be provided at the duct connection to the inlet
& discharge of fan.
All extraction points should have manual dampers for flow balancing. Motorized damper shall be
used for isolation of non-operating extraction points. Motorized damper shall be interlocked with
drive motor of main equipment of the operating stream.
Dust extraction system shall comprise of suction hoods.
All ducting and flanges joints shall be air tight in nature. Thickness of bends for the duct carrying
dust-laden air shall be properly selected.
Bends wherever used, should have radius of at least 1.5 times duct diameter.
1.2.4. DUST COLLECTING HOOD
Centerline of the hoods shall be located at the point of generation of maximum pressure during
formation of dust.
The hoods shall be adequately sized to collect all dusty air generated at the point.
Suction hood shall be suitably designed to have sufficient velocity across the face of the hood to
suck the dust from the source. Velocity in the hood must not be so high as to draw larger size
particles unnecessarily and shall be limited to 1.8 m/sec.
The hoods shall be made of MS plates of adequate thickness not less than 5 mm.
All hoods shall be provided with leak proof manual motorized butterfly type damper.

1.2.5. MOTORISED DAMPER


The motorized damper shall be used for isolation of non-operating extraction points. At the same
time it opens the air path for operating extraction points.
The actuator shall be linear type and shall be provided with thrust & position limit switches.
The actuator shall be designed considering the working pressure of not less than 500 mm wg.
1.2.6 ROTARY AIRLOCK
The rotary air lock shall be installed below the hopper of each bag filter. It shall be
Designed for continuous operation.
The rotary air lock shall discharge the dust collected in the bag filter hopper to the screw
Conveyor / discharge pipe efficiently without interference of atmospheric air into the bag
Filter hopper.
The rotary air lock shall be driven by geared motor and provided with zero speed switches.
******

DESIGN BASIS REPORT


FOR
DUST EXTRACTION SYSTEM

PART II
FAN CAPACITY CALCULATIONS FOR DE SYSTEM # DE-1 FOR SECONDARY CRUSHER
HOUSE

DESIGN BASIS REPORT


FOR
DUST EXTRACTION SYSTEM

PART III
FAN CAPACITY CALCULATIONS FOR DE SYSTEM # DE-2 FOR CRUSHER HOUSE