COAL HANDLING PLANT

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.
COAL FLOW DIAGRAM
JPL COAL MINES

CHP MINE END

CROSS COUNTRY
CONVEYOR

CHP PLANT END

COAL BUNKER

PULVERISER

BOILER
JPL Coal Handling Plant, CHP-2(Mine End)
JPL Coal Handling Plant, CHP-2(Mine End), Line diagram.
ABON CHAIN D.U.H.
SIZER FEEDER.
BC-1A,1B
BC-1E
TP-1 CH-2 SCREEN
BC-1F STEEL
BC-1N,1P BUN.
BC-1J HOUSE
TP-1A RBF
BC-2A,2B
COAL WASHERY
TP-2

BC-2C,2D BC7A,B
TP-6 TP-7
BUNKER BC-6A,6B BC-8
CH-1
BC-3A,3B TP-5
BC-5A,5B
TP-3 TP-4
BC-4A,4B Cross country conveyor
CHP-2(Mine End), System description:

The coal (1000mm aprx.) from coalmines has been dumped at DUH
where the material feed on to chain feeder (02 Nos) that carries the
material to Primary sizer (02 Nos). Primary sizer crushes the material
from 1000mm and converts in to 250mm and discharges the material on
to conveyer-1A/1B that carries the coal to TP-1 and discharges on to
conveyor-1C/1D. Through conveyor-1C/1D the material has been taken to
crusher house-2 where the material has been processed from 250mm to
50mm by the help of Ring granulator (02 Nos) and discharges on to
conveyor-1N/1P and conveyor-1J.

The material discharges on to conveyor-1J has been carried to steel

bunker of capacity (5000T) and then the material carries to coal washery
where the material has been washed and again fed on to conveyor-1F
which carries the coal to crusher house-2 and discharges on to conveyor-
1N/1P.
The material discharges on to conveyor-1N/1P has been carried to TP-1A
and discharges on to conveyor-2A/2B, which carries the material to TP-2
and discharges on to conveyor-2C/2D. Conveyor-2C/2D carries the
material to RCC bunker floor and then the material fed in to bunker
hopper with the help of traveling tripper (02 Nos.). Then the material
from hopper has been discharged to conveyor-3A/3B through rod gate
and weigh feeder. Conveyor 3A/3B carries the material to TP-3 and
discharges on to conveyor 4A/4B which carries the coal to TP-4 and
discharges on to conveyor-5A/5B. Conveyor-5A/5B carries the material to
Crusher house-1 and discharges on to roller screen( 02 Nos.), then Ring
granulator(02 Nos.) which processing the material from 50mm to –
20mm. And discharges on to conveyor-6A/6B, but the undersized
material if any are directly discharges on to conveyor-6A/6B from roller
screen. Conveyor-6A/6B carries the material to TP-6 and discharges on to
conveyor-7A/7B which carries the material to TP-7 and discharges on to
conveyor-8 which carries the material to TP-5 and discharges on to cross-
country conveyor.
 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.
 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:
i. ROM feed size up to 1500 mm (60”)
ii. Capabilities in excess of 10,000 mtph
iii. Minimal fines creation
iv. Insensitive to clay and sticky materials
v. Pre-scalping of undersize not required
vi. Exceptionally low headroom requirements
vii. Simple infrastructure requirements due to minimal dynamic loads placed on the supports and structure
viii. Ability to start up under a full load
ix. Long wear life of consumable components due to positive bite and minimal feed slip.
 COAL CRUSHER- Ring Granulator.
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 after crushing coal is being discharged to bottom conveyor
through cage/screen plate. Coal sizes is maintained by adjusting the wear
plate.
• Coal will crushed into two stage, in first stage coal is crushed 250 mm to 50
mm and in second stage 50 mm to 20 mm.
NOS OF RING GRANULATORTYPE CRUSHER – 04 Nos.
Model: 1017U
Capacity: 1000 TPH.
Manufacturer: L&T Limited.
BELT CONVEYORS – 1200 width (6282 R mtr.)
• 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
DUST SUPRESION SYSTEM – 02 Nos.
Make: Kaveri Products
Manufacturer: Kaveri
Supplier: FFE Minerals, Chennai
TRAVELLING TRIPPER – 02 Nos.
Make: Domacls products
Type: Motorized Traveling type
Capacity:1000 TPH
Travel speed:15 m/min
SUSPENDED MAGNET – 02 Nos.
Model: SMNR- 135/ 50 OA, SM 1 and
SM-2
Manufacturer: Power Build limited
VIBRATING SCREEN – 02 Nos.
Type- Spring mounted,
Capacity- 500TPH, mounted at screen
house .

METAL DETECTOR – 02 Nos.

Type: Electronic coil
Manufacturer: Electromag Device
PVT. Ltd

INLINE MAGNETIC SEPARATOR – 3 Nos.

Type: Electro Magnet, Inline
arrangement.
Make: Power Build limited
mounted on Bc-3A ,3B, BC8
JPL Coal Handling Plant
CHP-INSIDE PLANT
 COAL FLOW DIAGRAM – CHP INPLANT

DUH

Suspended
CONV 1 Magnet in CONV 2
Pent
TP 1
House

Stacker-
Reclaimer
StockPile
TP 3A

CONV 5

StockPile
CONV 5A TP 3 CONV
3A/B
TP 4A CONV 6

ILMS
CONV
4A/B

TP 4

TP 5
TRAVELLING TRIPPERS ON BUNKER
FLOOR
 System Description:
(A)Coal collected from DUH is discharged through rod gate, rack & pinion gate & vibro feeder to
conveyor –1 which carry the material to TP-1 and discharge the material to conveyor-2.
Conveyor-2 carries the material to TP-3 where the material has been discharge to
conveyor-3A/3B and conveyor-5 through flap gate.
The material discharge to conveyor-3A/3B has been carried to TP-5 where the material has
been discharge to conveyor-4A/4B and then it carries to boiler bunker and traveling
tripper (04 Nos, 02 nos with conv.-4A & 02nos with conv-4B) has discharged the material
to bunker hopper.
The material discharge to conveyor-5 has been carried to stacker where the material kept
stock at coal storage yard located at both side of stacker. At the time of feeding of coal from
the coal storage yard, the reclaimer take the coal from storage yard through bucket wheel
and feed on to conveyor-5 which carries the material to TP-3A where the material discharge
on to conveyor-5A. Conveyor –5A carries the material to TP-4A and discharge on to conveyor
– 6 which carries the coal to TP-4 where the material has been discharge on to conveyor-
3A/3B and the material has been carried to bunker hopper as mentioned above.
B) The material collected from cross-country conveyor at TP-3 has been discharge on to
conveyor-3A/3B and conveyor-5 through reversible belt feeder. The material discharge to
conveyor-3A/3B and conveyor-5 has been processed to bunker hopper as mentioned above.
 Stacker & Reclaimer
System Description:

A reclaiming and stacking system for conveying bulk material has an elongated yard conveyor
for moving the bulk material in the longitudinal direction of the yard conveyor; a rail-mounted
undercarriage straddling transversely the yard conveyor; first and second booms supported, at
their respective inner ends, on the undercarriage. There are further provided first and second
boom conveyors supported on and extending along the first and second booms, respectively; a
bucket wheel supported at the outer end of the first boom for removing bulk material from a
pile spaced from and along the yard conveyor and discharging it onto the first boom conveyor
at the outer end thereof; a central chute supported within the outline of the undercarriage
and having a discharge end oriented towards the yard conveyor; a first transfer arrangement
for directly transferring bulk material from the inner end of the first boom conveyor to the
inner end of the second boom conveyor; and a second transfer arrangement for transferring
bulk material from the inner end of the first boom conveyor into the chute for deposition onto
the yard conveyor.
 INSTRUMENTATION USED IN CHP
 Protection instruments
 Measuring instruments
 Control room instruments

Protection System
1. Zero speed switch
2. Sway system
3. Pull cord
 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
 JPL Coal Handling Plant-3
Coal handling plant has a singe pipe conveyor system 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
 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
 Advantage of steel cord belt
• Steel cord belts consist steel cords between top and bottom rubber
layer with phoenotec reinforcement which have following advantage
over conventional nylon ply belt conveyor.
• High tensile strength:-The High tensile strength of steel cord belt
for much higher working tension requirement as compared to
conventional belt.
• Smaller Pulley Dia: High longitudinal flexibility require smaller pulley
dia
• Excellent Troughability: Steel cord belt even with very high strength
it perfectly conforms to the contour deep toughed idler this insure
proper belt training and maximum capacity utilization
• Long Life: steel cord belt provide long life by utilizing the high fatigue
strength of steel cords
 Specification of Cross Country Pipe Conveyor

Supplier: M/S Macmet India ltd

Designing: M/S Bridgestone
Engg Support: Prof. Manfred Hager,Germany

Total Length of Pipe Conveyor : 6948 Mtr

Belt Specification: Width: 1800 mm, Weight: 55 Kg/Mtr, Pipe Dia:500 mm,
Speed: 3.75 m/sec
Steel cord belt ST1800 x 8mm top x 5 mm bottom FR
Motor Rating: 4 x 650 KW, 690 volts
Belt Supplier: M/s Phoenix Germany
Materials Handled: Crushed Coal of –20 mm size

Belt Capacity: 1500 MT per Hrs

 Line Diagram of Cross country Pipe conveyor

Primary drive

Motor-1
Mot

Motor-2 Tail drive

Motor-3

Sec drive Balance Wt

Rope wire

Take-up Trolley Arrgangement

 System description:

The pipe conveyor of length 7 Km will be carrying coal from the belt conveyor no.8 of
mine end CHP to the plant end CHP at 1500 tph on top side and will return empty
from the plant end CHP to the mine end on bottom side. The pipe Dia and the
conveyor is 500 mm and 3.75 mps respectively.
The pipe conveyor at the ends will be flat from the receiving zone, the troughing of
the belt will be gradually increased and ultimately the pipe will formed through pipe
shape keeping modules.At discharge end ,pipe will open out and will gradually
become flat at the terminal pulley.
Total nos of motors: 4
3 nos at drive end (plant end) and 1 nos at tail pulley(mine end)
Each of motor are of 650kw,690v with 1500 rpm rated speed and each motor will run
through separate vvvf drive units.
 Operation and control
Over all operation and control of cross country conveyor pipe conveyor
will be normally performed through 2 nos PLC based operator consol
with 20 “ monitor and one nos laptop based engineering station. The
main PLC is provided in the CHP control room in plant end and a remote
PLC I/O unit is located in the mine end. The main PLC is connected with
remote PLC I/o through optical fiber cable.
The additional one no. control desk is also provided in the CHP control
room for operation of pipe conveyor so that the conveyor can be started
or stopped through the desk.
 Startup of cross country conveyor

The conveyor will start permissive are:

•The discharge end conveyor is (on) and signal is available in PLC
•All four motors are healthy and not in local maintenance mode
•All four VVVF drive are healthy
•All four transformer are healthy
•Feeding conveyor at mine end (BC-8) is stopped
•Limit switches in take up area and zero speed switches are healthy.
•If above condition are met the conveyor is ready for sequential start. Indication will be
available and start signal can be given either from the OWS or control desk push button.
•Before starting of the conveyor an audible warning through hooter at TP-3 and TP-5 will
come to warn the operators working in any of equipments of conveyor.
 SHUT-OFF PROCEDURE
NORMAL SHUT-OFF
The stopping of the conveyor will also be controlled through VVVF units
under normal conditions. On giving the ‘Stop” command the feeding
conveyor at the mine end will stop first and the succeeding pipe conveyor
and discharge conveyor at the plant side will stop in that sequence after a
time lag.
EMERGENCY SHUT-OFF
During emergency condition that is when “Emergency switch” is actuated or
power failure occur, then there will be no controlled stopping. This sudden
stopping of the system will trigger the “Disk brake” provided on the
capstan shaft in take-up, through gear & pinion arrangement. This will
arrest movement of trolley under emergency condition. After 10 seconds,
the brake will be gradually released so as to balance the tension of the
system and the applied tension.
 RF Communication Scheme Between The PLC and Maintenance Trolley
• In order to facilitate the RF communication between the main PLC and the maintenance
trolley a data link radio with a small PLC operating in a specified licence free frequency band
will be provided in each maintenance trolley.
• Another radio link unit will be located in the main CHP control room which in turn will be
connected with the main PLC for the cross country conveyor located in the control room
• The radio link unit will have compatible connectivity with the main PLC unit.The radio link
unit will have transmission range of about 15 km . The antenna for the radio communication
system in the maintenance trolley will be located suitably on the side / top of the unit
located in the control room the antenna will be located suitably in the CHP control room
building.
• As per repair / maintenance requirements the maintenance trolley traveling on fixed rail will
be started by the operator and moved to the desired destination.On reaching the destination
the trolley will be stopped. If the operator cum maintenance man feels that the conveyor
need to bestopped , then he will operate a switch provided in the trolley for that purpose.
• The switch contact will initiate the PLC input / output in the trolley and transmit the data
through the radio link in the trolley to the radio unit in the main control room which in turn
will initiate the main PLC circuit for automatic stopping of the conveyor. The conveyor will
now stop as per the logic provided in main PLC.
• Similarly after completing the repair / maintenance work the opertor of the trolley again
operates a switch and the data will be transmitted to the control room PLC , giving clearance
for starting of the conveyor by an operator.
 MAINTENANCE TROLLEY

• Two no. mobile self driven trolleys will be provided for inspection , servicing
and maintenance of the conveyor .Drive for each trolley will be through
diesel engine , coupling , gearbox and wheels connected by chain & sprocket
arrangement .Trolley will be traveling along the tracks laid over the
conveyor gantries .Side guide wheels will be provided for stability and
additional safety of the trolleys .Necessary safety arrangements will be
incorporated in the trolley design including parking clamps.Operator cabin
will be adequate to accommodate four personnel in case of any major
maintenance work.

• The trolley platforms will be designed for good access to all parts of the
conveyor for the maintenance and servicing The trolley will be provided
with necessary lighting arrangement for night operation.Communication
between the trolleys and control room will be through walky talky.Provision
for carrying out welding work will be provided in the trolleys.Two no.
parking station , one each at power plant end and mine end will be provided
for the trolleys
 The pipe conveyor specifications are as follows
Conveyor length, pulley centers: 7 KM
Overall lift : 15.2 m
Belt speed : 3.75 m/s
Conveyor capacity : 1500tph (initial);
2100tph (future)
Belt Breaking Force : Less then 26.4 KN
Pipe diameter : 500mm
Belt width x thickness : 1800mm x 18.4mm
Belt specification and covers : ST1800 ,130 steel cord ,
5.5 mm dia.
Horizontal radius: 700m
Vertical inclination (max.): 300 m
Horizontal deflection : 90 degrees
Location of take- : up Head-end
Type of take-up : Horizontal trolley, gravity mass
Take-up travel distance: 25,0m live; 19,0m available
Take-up mass : 12 tons
Belt type; Steel cord conveyor belt Phoenix ( Germany
)
Installed power : Head=3x650kW; Tail=1x650kW VVVF Drive
High tension and drive pulley diameters : 1000mm
High tension pulley face width: 2000mm
Gearbox ratio (nominal): 20: 1
 Vulcanizing Arrangement
Phase-1
In Phase-1, laying of top and bottom belts between the discharge end (TP-3) and girder GR63 will
be done. The belt will be loaded on Belt decoiling equipment in front of the discharge (Primary
drive) Pulley. The belt pulling equipments viz. The derrick post, Deflection pulley, Electrically
operated winch, Guy ropes for stabilization and arresting ropes will be arranged below GR63 as
indicated in the sketch. The winch, deflection pulley and 2 nos. of guy ropes in position, will be held
in position by mounting them on R.C.C. Concrete blocks.
Wire rope of suitable size and length will be laid along the top pipe belt through the rollers fitted in
the modules. One end of the rope will be fixed to the winch and the other end to the belt through
special ‘conical pulling device’. This conical pulling device helps to form the pipe configuration of
the belt. Heavy duty straight roller need to be provided at the entry point of the belt to avoid
damage to the belt and to the structure as well.

The belt will be slowly pulled into the segmental rollers by operating the winch. The belt in pipe
configuration will be strapped at every 20 m to avoid the change of overlap. Similarly, the belt
edges will be specially treated to reduce the friction between the belt surfaces .
After one full length belt laying is completed, the next belt will be loaded on the de coiling
equipment and both the belts will be joined on the ground by hot vulcanizing. The second belt will
be then pulled on to the conveyor structure. In the same manner, the top and bottom belts
between the discharge and GR63 will be laid.
Phase-2
The decoiling equipment and the vulcanizing equipments will be shifted to GR63 and the belt pulling
equipments to GR137 and grouted firmly.
As described earlier, the belts both the top and bottom pipe conveyor between these two box
girder locations will be completed.

Phase-3
Laying of belts between box girders GR 137 and GR 243 will be carried out in the same way as
mentioned above.

Phase-4
Laying of belts between box girders GR243 and the receiving station (TP-5). Afterwards the twist if
any, in both the bits right from the discharge end to the receiving end will be manually removed so
that the overlap of the carrying belt is on the top and that of the return belt is at the bottom of the
pipe.
The free end of the beltings in girders 63, 137 and 243 will be jointed together at the ground after
inserting the required number of modules around the concerned belts.

Pre-Final Joint
Both the top and bottom belts will be pulled towards the receiving end and the box girders 63, 137
and 243 have to be assembled to the conveyor system. Pre-final joint will be done on the conveyor
near the receiving end.

Final Joint
The belts will be tensioned, clamped and final joint will be done on the discharge structure of the
conveyor.