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Coal Transportation And Handling Presentation Transcript
1. Coal Transportation & Handling
2. -As Coal, is the prime input for a thermal power plant, adequate emphasis needs to be given for its proper handling and storage. -It is equally important to have a sustained flow of this fuel to maintain uninterrupted power generation. -This Presentation describes the existing systems of coal transportation and handling.
3. Grades of Coal
4.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
5.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.
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
5.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.
6.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.
7.COAL UN LOADING
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.
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.
7.COAL UN LOADING
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.
8.TRACK HOPPER
9.COAL-HANDLING 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 only for crushed coal.
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 only for crushed coal.
10. COAL HANDLING PLANT LAYOUT
11.Coal Handling
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,
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,
12. Coal Handling system equipment
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.
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.
13. Track hopper to crusher 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.
14. In the Crusher 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.
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.
14. In the Crusher 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.
15. PULLEYS
Made of mild steel.
Rubber coating is used to increase friction
factor between belt & pulley (rubber lagging)
Made of mild steel.
Rubber coating is used to increase friction
factor between belt & pulley (rubber lagging)
16. Belt Protection Equipment
Pull Chord
Belt Sway
Zero Speed
Chute block
Pull Chord
Belt Sway
Zero Speed
Chute block
17. Stacker – cum -reclaimer
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.
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.
18. Stacker – cum -reclaimer
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.
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.
19. STACKER-CUM- RECLAIMER
20. SEPARATING FOREIGN MATERIAL FROM CONVEYOR
21.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.
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.
22. IMPORTANT FACTORS FOR STORAGE OF COAL
23. PREDICTION OF SPONTANEOUS COMBUSTION
24. MANAGEMENT OF COAL STOCKYARD
Proper coal-air interaction to avoid auto- oxidation and spontaneous combustion.
Close monitoring during march-june.
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.
Proper coal-air interaction to avoid auto- oxidation and spontaneous combustion.
Close monitoring during march-june.
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.
25. MANAGEMENT OF COAL STOCKYARD (CONTD.)
Stacking in trapezoidal shape, not in conical shape.
Height of stockpile not more than 9-10m (indian coal).
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.
Stacking in trapezoidal shape, not in conical shape.
Height of stockpile not more than 9-10m (indian coal).
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.
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