INDUSTRIAL ENGINEERING

8/17/2012

APPLICATION IN

COAL HANDLING PLANT

1

 Transportation of Coal.  General Layout of CHP.  Availability of Coal in India.INDEX Introduction.  Defining the problem  Root cause analysis  Developing the solution  Implementation  Benefits  References  2 8/17/2012 .

 To Stack the coal to coal yard. 3 . H.Plant)  Which properly handles the coal from its receipt to transferring it to bunkers. P. Objective of CHP : To  supply the quanta of processed coal to bunkers of Coal mills for Boiler operation.INTRODUCTION 8/17/2012  What is CHP?  CHP (C.Handling.Coal.

47.10 .05 34.57 19. ( K Cal / Kg.34.06 .97 23.57 .V.69 .92 .14 4 40.40.  Blending Is Done To get Average D Grade.69 28. Mostly E and F grade coal used in India.  8/17/2012 Grade C.AVAILABILITY OF COAL IN INDIA. )  6200 5601-6200 4941-5600 4201-5940 3361-4200 2401-3360 % Ash + Moisture A B C D E F 19.14 .23.28.

waterways. Ropeways. Railways. Roadways. Best and Cheap facility at Doorstep 8/17/2012 • • • • 1. 4. Available only for TPS nearer to coal mines Fear of thief waterway may not be possible till TPS and Problem of recalling arises if coal dip in water 5 . 2.TRANSPORTATION OF COAL 4 ways of Transportation. 3.

6   . 8/17/2012 Demurrage calculations on coal Rakes: We receive the coal wagons in the form of rakes (55-60 wagons in each rake). Free time is calculated from the receipt of written intimation of coal rakes from power plant to the railway. from Receipt of coal.100 / wagon / hr. Rate of demurrage is Rs.BY RAIL WAY  80-90% of the requirement is fulfilled by this way.  Free time normally 7 hrs.

Belts Vibrating Screens Crushers Tripper Trolley Bunkers 7 .GENERAL LAYOUT OF CHP 8/17/2012 Wagon Tippler Hopper Crusher House Surge Hopper Feeder Conv.

4 m/sec oSpeed After Crusher 2.7 m/sec 8 .CONVEYOR BELT DRIVE SYSTEM 8/17/2012 Fusible plug Head End Pulley Motor G/B Fluid Coupling Filled with 3/4th oil Tail End Pulley Belt Speed oSpeed before crusher 2.

A HEAD END TAIL END Ammete r CONVEYOR CHUTE BELT .B MOTOR MOTOR 9 .DEFINING THE PROBLEM COAL TRANSFER POINT BELT .

A COAL HEAP Ammete r COAL CHUTE CHOKE -UP BELT .ROOT CAUSE ANALYSIS BELT .B NO BUNKARING 10 .

Head End 6”x 4” Window Hole Motor Floor . Belt Coal Transfer Chute Belt Conv.DEVELOPING SOLUTION Conv.

Belt Coal Transfer Chute Belt Conv.DEVELOPING SOLUTION Conv. Head End 6”x 4” Window Pad Motor Floor .

DEVELOPING SOLUTION ELECTRICAL CIRCUIT EXTENTION Local Stop Push Button Limit Switch From C/R To control Room Cable extended Local Terminal .

DEVELOPING SOLUTION .

IMPLEMENTATION Coal Flow 6”x 4” Window Pad Limit Switch .

IMPLEMENTATION Coal Flow Modified chute pad pressed out side Limit Switch Chute Choke up due to Wet Coal .

IMPLEMENTATION Coal Flow Modified chute pad pressed out side Limit Switch Chute Choke up due to Wet Coal .

 18 .  Life of conveyer belts.BENEFITS 8/17/2012 Reliability of the coal handling system is increased.  Down time of the system is reduced.  Saves manpower required for cleaning and system restoration.  Electrical power consumption is reduced as there is no overloading of motors.  Demurrage charged by Indian railways due to delay In unloading is reduced. gearbox and motor is increased by reducing frequent overloading.

8/17/2012 Thank you 19 .

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