COAL MINING FIELD TRIP (MI 38018)

COAL HANDLING PLANT (CHP)

2009 -10
NORTHERN COAL FIELDS LTD., SINGRAULI ,M.P, INDIA

UNDER THE GUIDANCE OF: SUBMITTED BY :

PRITI RANJAN SINGH (07MI3010)
Prof. Subir Kumar Mukhopadhyay SUBHASH RANJAN (07MI3011)
Prof. Debasis Deb PULLAIAH NARAPOGU (07MI3012)
Prof. A.K. Patra SURAJ PRAKASH(07MI3021)
Preview of Mining Operations in NCL.
What is a Coal Handling Plant all about.
Design Outline.
Detailed Outline of CHP.
Main Plant units.
Main Auxiliaries of CHP.
Capacity Calculations for a CHP.
CHP problems.
Use of Computers in CHP design.
CHP is (C- Coal, H- Handling, P- Plant) a plant which handles the coal from
its receipt to transporting it to Boiler and store in Bunkers. It also processes
the raw coal to make it suitable for Boiler Operation.

Extent of work: - In brief we can say that receipt of coal from coal mines,
weighing of coal, crushing it to required size and transferring the quanta of
coal to various coal mill bunkers. This is the responsibility and duty of the
CHP and its staff.

Receipt of Coal:-

Normally Thermal Power Station receives the coal by three modes of

transportation.
1. By Railway (80-90% of the requirement is fulfilled by this way)
2. By Road ( if required 5-10% of the requirement is fulfilled by this way )
3. By Arial ropeways
Fig: Outline of a Coal Handling & Preparation Plant
 Various units of a Coal Handling and Preparation Plant :
Conveyor belt
Or Loader Screen
ROM PR. Sr.
Crusher Crusher

 Jaw  Static(Grizzly)
 Gyratory  Mechanical  Cone
 Hammer Mill  Revolving  Roll
 Vibratory  HammerMill SILO

Design Considerations :
 Product Specifications.
 Energy Considerations.
 Output and Input Characteriics.
WAGON

* Most of the present plants are first designed and simulated in Computers before
their actual construction.
JAW CRUSHER-
Jaw crusher is a primary type of crusher which
has two jaws ,out of which one is stationary and
attached rigidly with the crusher frame whereas the
other jaw moves by a small throw forward and
retarded back successively to crush ore or rock
boulders.

GYRATORY CRUSHER-
Gyratory crusher mainly consists of two vertical
conical or domed shaped crushing member.The
inner member(the apex of which is pointing
up) gyrates around the vertical axis inside the
stationary outer crushing member(apex of
which pointing downward).
SCREENING
.
Screening is the process of separation of various uniform
sizes ( varying from several centimeter to 20 mesh) from a
mixture.
The screen are also used to feed a particular crusher or
grinding mills with particular sizes of particles passing
through the screen after eliminating the oversize particle
STATIONARY SCREEN GRIZZLIES
from the mixture .
Various types of screens can be listed as follows :-
1)STATIC SCREEN

2)MOVING SCREEN
a. Trommels
b. Vibrating screen
c. Shaking screen .

Screening Efficiency = Vibrating Screen

(fine materials or grains those are passed through the screen from the feed / Quantity of fines)
Amount of feed
SILO
Silo is a huge structure for
storing different bulk materials
including coal. It uses a rapid
loading system to load coal to
the wagons .

The Silo at the Dudhichua mine

was cylindrical in shape. It
receives the coal by the
conveyor after the whole
processes of crushing and
screening performed .Then the
coal gets loaded to the rail
wagons ,which transport coal to
the power plant.
Major auxiliaries of CHP:-
Wagon Tipplers:-
These are the giant machines having gear boxes and motor assembly and
are used to unload the coal wagons into coal hoppers in very less time
(e.g. 20 wagons/hr. or more).

Vibrating Feeders:-
These are electromagnetic vibrating feeders or sometimes in the form of
dragging chains which are provided below the coal hoppers. This equipment is
used for controlled removal of coal from coal hoppers.
Conveyor Belts :
These are the synthetic rubber belts which move on metallic rollers called idlers
and are used for shifting of coal from one place to other places.

Coal Crushers:
We receive the coal in the form of odd shaped lumps. These lumps are to be
crushed to required size. These lumps are crushed by coal crushers.

Trippers:
These are the motorized or manually operated machines and are used for
feeding the coal to different coal bunkers as per their requirement
Electromagnetic Separators:-
Electromagnets are used for removing of Iron and
magnetic impurities from the coal.

Dust Extraction System:-

This system is provided in CHP for suppression of
coal dust in coal handling plant.

Gas Extractors:-
Gas extractors are provided at the bunker level to
remove all types of poisonous and non poisonous
gases from the working area.
 METAL DETECTOR
It detects the presence of any
magnetic material in the coal.

FLOP GATE
This is a one IN two OUTs gate with
the intention of separation.

SLIDING GATE
It is flat bedded Gate having
horizontal movement. It transfers coal
from the crusher box to the apron
feeder

GROUND BUNKER

Plough feeders are present underground inside the ground bunker.

APRON FEEDER

The capacity of a crusher can be increased by feeding

material(coal) with uniform rate.An Apron type feeder is
suitable for use ahead of a primary crusher.

PLOUGH FEEDER

A Plough Feeder is capable of travelling back and

forth along the entire length of the hopper and
transfer the coal uniformly onto the conveyors below.

CRUSHER BOX
Crusher Box or else called as crusher house where crushing takes place.

MAGNETIC SEPARATOR
As from the name it separates out the magnetic material from the coal.
Operational Cycles:-
1. Normal Bunkering cycle.
2. Stacking cycle.
3. Reclaiming Cycle.

Normal Bunkering Cycle:-

Shifting of coal received from coal wagons directly to coal bunkers is normal
bunkering cycle.

Stacking Cycle:-
When there is no coal requirement at coal bunkers even then CHP has to unload
the received coal which is stacked at open ground called yard. This is stacking
cycle.

Reclaiming Cycle:-
As and when coal wagons are not available the requirement of coal bunkers is
fulfilled from the stacked coal this is reclaiming cycle.
The capacity of the CHP is decided by the Coal Requirements for its
customers.
Sample Capacity calculation for a Thermal Power Plant producing 3260 MW

calorific value of sub bituminous coal =14,000 kJ/ kg

overall efficiency of thermal power plant=33.3%
quantum of coal (TPH) required to produce 500 MW =

TPH=(3X500X60X60)/14000 =390(approximately)
 1) Coal Consumption per 1630 MW unit 1272 TPH

2) Coal consumption for 2×1630 MW units 2544 TPH

3) Daily Coal consumption for 2×1630 MW units 61056 T

4) No. of streams provided for the Coal Handling Plant 2

5) Since plant is to be operated generally on design (61056 /(2 x 7))T
coal, hence capacity of each coal stream = 4361 TPH
considering 2 no. shift daily 7 hrs. per shift
6) Capacity of each coal stream chosen considering 5233 TPH
120% margin over worst coal requirement
7) Hence capacity of each coal stream 5230 TPH

* Assuming a 500 MW unit uses quantum of 390 TPH coal.

 Name of the Existing CHP Capacity New CHP/Silo Planned
Project (M tes) (Addl. Capacity in M Tes)
Amlohri 4.0 6.0
Bina 4.5 1.5
Dudhichua 10.0 5.0
Jayant 10.0 5.0
Jhingurdah 3.0 -
Kakri 2.5 -
Khadia 4.0 6.0
Nigahi 5.0
5+5=10.0
Krishashila - 4.0
Block-B - 3.5
Total 48.0 36.0
Loading Operations in Singrauli Mines : SILO – Railway Wagons.

Trial Loading Operations at Phase II Loading Operations at Phase I

SILO SILO
7/11/2013 27
Problems in a Coal Handling Plant :
The oxydation of coal at stock yards
The flow problems during rainy seasons
Sticking problems at shutes and bunkers
Problems combined with mixing different sized and
different quality coals
The abrasion of coal handling equipment
Spillage during handling

Setting of a Coal Handling Plant is a very expensive and a difficult affair.

Hence before setting a plant , all the factors are considered.
Hence a CHP plant is first modeled and simulated in a processing plant
simulation software .