PPT ON COAL HANDLING PLANT

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Coal Handling Plant  Presentation Transcript

1.Coal handling plant
Coal
Unloading system
Conveyor system
Crushing system
Feeding system
Stacking system
Magnetic separator/ metal detector
Bin/chute vibratory system
Coal weighment
Coal sampling
Fire fighting system
Dust suppression system
Dust extraction system

2.CATEGORIZATION OF COAL

3.COAL CHARACTERITIC
Moisture 6-7%
Ash 24-33%
Volatile matter 24-28%
Gross Clorific Value 4778-4944 kcal/kg
Hardness index 45-50
Density 0.8MT/m3
Size 250mm

4.Coal unloading

5.Wagon placement system

6.Conveyor system
Idlers – Troughing, Return, Impact, Self aligning
Pulleys- head, tail, bend, snub pulleys
Counter weight/ take up
Gear box, fluid coupling, hold back, scraper
Duct, flap gate, liners, deflector plate, skirt board
Dust suppression, fire fighting
Pull cord, zero speed , belt sway , EPB

7.Conveyor system

8.Metal detector, online ms

9.Conveyor system

10. Crushing system
Ring granulator
Primary crusher/beaker

11. How Feeders Work and Benefits Vibrating feeders are classified in two sub-groups, these being Electro-magnetic feeders and Electro- mechanical feeders. Electromagnetic models incorporate an electric motor which energies a magnet, enabling it to activate multiple times per minute. Every time the magnet is energized it creates a 'stroke' action which resonates through the feeder trough and vibrates the materials in a uniform, high controlled flow towards the end of the trough. As there are minimal or no moving components in these feeders, they are exceptionally reliable units that offer precise feed control where batch weighing and flow control needs to be precise. Electro-mechanical feeders are also reliable units with many models offering economical value compared to electromagnetic models. Material flow is courser and the occasional preventative maintenance will need implementing. Instead of magnet activation, these feeders may utilize an eccentric motor, vee-pulley, cam and bearing arrangement to introduce the vibrating action. These units are capable of operating in the harshest conditions and are unrelenting in moving massive volumes of coal, rock or aggregates.

12. Feeding system

13. V feeder, crusher, hyd coupling, RPG

14. Stacking system

15. Dust extraction system

16. Coal sampling unit, belt weigher

17. Stacker-reclaimer
A stacker usually operates on a rail-like structure with movable wheels, but the main operation is performed on a fixed place.
Stackers are used to stack into different patterns, such as cone stacking and chevron stacking. Stacking in a single cone tends to cause size segregation, with coarser material moving out towards the base. Raw cone ply stacking is when additional cones are added next to the first cone. Chevron stacking is when the stacker travels along the length of the stockpile adding layer upon layer of material.
The controlling system used is typically a PLC (programmable logic controller) with an HMI (human-machine interface) for display connected to a central control system.
Other than stacking, the stacker does three basic movements: luffing, travelling and slewing.
Luffing: This is vertical movement (that is, up & down)by hydraulic cylinders .
Travelling: The stacker moves on a rail track. All the controls are in the controller's cabin which is above the boom conveyor. The new stackers can be controlled remotely.
Slewing: This is the movement of the stacker around its central axis (that is, rotary movement). This allows aligning or placing the stockpile in the required area as per requirement. This works mostly by swel penion which rotates around a swel base. This type of gear assembly is called the sun and planet.
Most stackers are electrically powered by way of a trailing cable. There are basically two types of cable trailing: PCRD (power cord rotating drum) and CCRD (control cable rotating drum). Pendulum adjustments are made to ensure the proper alignment of these cables while the stacker is travelling.

18. permissive
Belt status ready (pull cord, BSS, EPB, Control supply)
Discharge gate on running belt open and that belt is running

19. interlock
In case of any belt trip, entire system behind except crusher will stop
Any other belt of pair will not start on the same discharge belt except 1A&1B
Corresponding feeder will trip if any belt trips

20. protection
Belt & following system except crusher will trip in case of operation of BSS
In case of excessive belt slipage, low speed due to over load or otherwise, belt not running although motor running, belt snapped than belt and following system will stop through zeero speed switch
Overloading of more than 600T/hr
Motors are protected against over load, short circuit, single phasing

21. Operation of CHP

22. Operation of Paddle Feeders
The Paddle Feeders feed the coal on the conveyor belt from the Track hopper at a controlled rate. The paddle blades projected in the hopper slot scoop the coal from hoppers and discharge it on the conveyor belt running below.
The following points need to be checked before taking any paddle feeder into service.
a) The paddle arms are free from any obstruction.
b) There is no leakage at gearboxes and fluid couplings and the oil levels are correct.
c) There is no leakage of hydraulic oil, in the case of hydraulically driven paddle feeders, and the oil levels are correct.
d) The cable reeling drums for correct winding and unwinding.    
e) The paddle feeder is operating only in interlock mode.

23. Various conveyors are provided for transporting the coal from Track hopper to Bunkers.
The following precautions are to be taken before taking any conveyor into service:
a) There is no oil leakage at gearboxes / fluid couplings and the oil levels are correct.
b) The Discharge and Receiving chutes are free from jamming and choking.
c) The Flap Gates are in correct positions.
d) All inspection doors are in the closed position.
e) All pull-cords are reset and the EPB is released and ensure that all protections are healthy.
f) The Alarm Siren is in working order.
g) Communication facility is available.
h) The lighting is adequate.
i) No Permit To Work (Isolation) is pending against that conveyor.

24. Operation of Stacker Reclaimer
The Stacker Reclaimer is provided to stack the excess coal received from the mines and to reclaim the coal, as and when required.
The following points need to be checked before returning Stacker Reclaimer into service:
a) The track is clear of obstructions.
b) There is no leakage from gearboxes, fluid couplings & hydraulic system. The oil levels are correct.
c) The availability of power supply is checked.
d) All operations e.g. travel; slewing, luffing etc. are available.
e) Brakes are clean and functioning correctly.
f) CRD cable is free from damage and any obstruction and is tensioned correctly.

25. Operation of Crushers
Ring Granulator type crushers are provided to crush the coal generally from (-) 250 mm/100 mm size to (-) 20 mm size. The following points need to be checked before returning any crushers to service:
a) The crusher shall be clear from any jamming.
b) All inspection doors are in the closed position and locked.
c) There is no leakage at gearbox and fluid couplings and the oil levels are correct.

26.Operation of Trippers
Trippers are provided on coalbunkers to receive coal from the conveyors and feed it to the bunkers. The tripper is mounted on rails and feeds coal to the bunkers for use on all the units. The following checks are to be carried-out before taking the tripper into service:
a) The availability of supply.
b) That the brakes are clean and functioning correctly.
c) The tripper discharge chute is free from jamming/blockage.
d) That the CRD cable is free from any obstruction and is tensioned correctly.