FOCUS ON COAL AND

ASH HANDLING PLANT

BY
N.K.SRIVASTAVA
22nd MAY,2012
CAPACITY ADDITION ANNOUNCED

Announced Capacity

920.7 Gigawatt 914 Projects

CONTINUED

Fuel Projects Capacity (MW)

Coal 571 683,402
Under Construction 124 116,761
Under Implementation 111 113,044
Under Planning 336 453,597
Gas 112 111,366
Under Construction 20 10,259
Under Implementation 18 8,465
Under Planning 74 92,642
Hydro 220 86,246
Under Construction 48 13,417
Under Implementation 30 8,377
Under Planning 142 64,452
Nuclear 11 39,700
Under Construction 3 4,800
Under Planning 8 34,900
Total 11 39,700
Under Construction 195 145,237
Under Implementation 159 129,886
Under Planning 560 645,591
Grand Total 914 920,714
Key Clearances

Under Under Under Grand

Project Status
Construction Implementation Planning Total
Cap (MW) 145,237 129,886 645,591 920,714
Total 195 159 560 914
Land 181 126 71 378
Water 181 114 74 369
Environment 183 128 86 397
Financial 169 60 12 241
Equipment 183 58 13 254
Environment Clearance Pipeline

Announced Capacity

417 Gigawatt 370 Projects

Fuel Continues to Be the Biggest Issue

Fuel Pipeline for the Coal Sector

Plant Type Projects Capacity

Linkage 255 283,099
Captive 47 62220
Imported 30 47,500 203 Projects have applied for
Linkage but is pending
Linkage+Imported 26 35,532
Captive+Imported 5 5,770
Captive+linkage 32 36,360
Captive+Linkage+Imported 1 600
Not Finalized 175 212,321
Grand Total 571 683,402
 MAJOR PLAYERS
• Coal Companies (CIL)
• Railways
• Power Generation Companies
• CHP Equipment suppliers and contractors
 Major Issues
• Coal quality
• Coal Transportation
• Coal stock
• Competent contractors
 Coal Quality
• very variable
• ash content – system capacity, component life
• moisture & fines – flowability in hoppers, chutes,
housekeeping
• oversize quantity – delays in unloading ,
additional handling
• stones and trash – delays in unloading, removal
facilities, damage to equipment
 Coal transportation
• Bunching of rakes
 Coal stock
• Actual delivery less than requirement
• Imported coal
- handling
- blending with domestic coal
 CHP /AHP suppliers- Issues
• Limited numbers/Bunching of Orders.
• Shortage of skilled Manpower/Capabilities
• Core competency in executing Civil works
• Good Civil sub contractors.
• Fabrication works execution.
• Standardisation by Utilities
• Steel procurement/Availability of fronts
• Skewed Cash Flow strategies
• Interface issues with main plant& other
Vendors
Trends in manufacturing capacities of key CHP
and AHP players

• CHP manufacturing companies have augmented

their in-house manufacturing capacities to meet
the new challenges of capacity addition
programme of XII and XIII th Plan.

• Need for a good AHP player is there . Many

companies are trying to enter in the fray.
Key Technology Developments

L&T:
Wagon Shifters and Pushers :
Developed for reducing the space requirements in
outhaul side of Wagon Tippler Complex and to
reduce the unloading time. Revolutionary
development considering paucity of free hold land.
Wagon Tipplers:
 Development to meet the latest requirements of
RDSO G-33 specification, which has come into
force from 1st December 2010.
Key Technology Developments

• Hydraulic Drives for Conveyors –. Low / zero

running maintenance cost.
• Stacker Reclaimer bucket wheel & slew drives.
These will increase the efficiencies over the
electro mechanical drives, lower maintenance,
reduction in overall machine weight.
• Permanent Deck sheets for floor slab castings
against the conventional shuttering, leads to
faster construction.
Key Technology Developments

• Flow dividing concept in the junction towers, for

efficient blending
• Increased belt speed up to 4.8 m/sec.
• HT and LT cables are routed through conveyor
galleries, instead of cable trestles
• Single CHP for both phases of the power plant – e.g.
Adani Tiroda,etc.-High capacity CHP 3000-5000TPH
• Rapid unloading system for small Track Hopper
Recently executed projects, their highlights
and learning's

• Utilities are switching for Wagon Tipplers, to

address latest RDSO guidelines and ensure
minimum unloading rate of 25 tips / hr.
• Reduced Engineering approval time – for all the
customers
• Ensure faster availability of customers’ inputs – to
be done by utilities.
 Recently executed projects, their highlights
and learning's
• In recent times, most of the utilities are including the
Bunker TP’s in the scope of CHP Contractor to avoid the
delays in overall plant completion, e.g. Malwa CHP, DB
Power CHP.

• Overall CHP execution time has come down. CHPs are

now being executed in 20 months – e.g. Mahan CHP.

• Tuticorin Coal Handling Plant for NTPL (2 x 500 MW) -

port based power plant, includes marine piles, 2.2 km of
off Shore Conveyor with Hydraulic conveyor drives for
12 conveyors.
 TRENDS IN MANUFACTURING
CAPACITIES

-NO CLEAR TRENDS SEEN IN EXPANSION OF

MANUFACTURING CAPACITY IN INDUSTRY

-PLAYERS ARE GENERALLY STICKING TO CORE

AREAS
 KEY TECHNOLOGY DEVELOPMENT

- HIGH CONCENTRATION SLURRY DISPOSAL

SYSTEM

- DRY BOTTOM ASH SYSTEM

LEARNINGS FROM PROJECTS UNDER
- EXECUTION
-DELAYS IN ASH HANDLING SYSTEM:

 DELAY DUE TO EXECUTION OF CIVIL &

STRUCTURAL WORKS.
COLLABORATORS FULL FLEDGED NON
INVOLVEMENT.
DELAY IN PLACEMENT OF ORDERS FOR
BOUGHTOUT ITEMS.
NONAVAILABILITY OF EXPERIENCED & SKILLED
MANPOWER FOR PROJECT EXECUTION.
NON STANDARDISATION OF SYSTEM.
FINANCIAL CAPABILITIES OF CONTRACTORS.
THANK YOU
 KEY TECHNOLOGICAL
DEVELOPMENTS
- LATEST HIGH CAPACITY WAGON TIPPLERS
(CONFORMING TO RDSO G33 Rev.1)

-HIGH CAPACITY CHPs (3000TPH-5000TPH)

- HYDRAULIC DRIVE IN PLACE OF ELECTRO-

MECHANICAL DRIVE FOR MAJOR EQUIPMENTS
LIKE TIPPLER, STACKER CUM RECLAIMER
 TRENDS IN MANUFACTURING
CAPACITIES

- HAVE GENERALLY INVESTED IN EXPANDING

MANUFACTURING CAPACITIES TO CATER TO
HIGHER PRODUCTION VOLUME REQUIRED FOR
UPCOMING PROJECTS

- HAVE GONE IN FOR COLLABORATION/

ASSOCIATION/ JOINT VENTURES WITH VARIOUS
FOREIGN PARTIES TO EXPAND THEIR RANGE
RECENTLY EXECUTED PROJECT-
PROJECT- HIGHLIGHT &
LEARNING
-HIGH CAPACITY PLANT OPERATING SUCCESSFULLY.
-CAN PLAN FOR HIGHER CAPACITY CHP.
- GENERAL SHORTAGE OF SKILLED MANPOWER