1

2
 TYPES OF MATERIAL HANDLED

 Ports – Ship Loading & Unloading of Materials

 Steel Plants – Ore, Coal, Limestone etc.

 Cement Plants – Limestone, gypsum, clinkers etc

 Power Plant – Coal

 Mines – Excavation, Mining & Handling of Minerals & Materials

 Food Industry – Grains ( pneumatic conveying)

 CONCEPT OF BULK MATERIAL HANDLING IN PORTS

 IMPORT OF BULK MATERIAL

 Cokeing coal from Australia , Indonesia & Newzeland.
 Thermal coal from west Bengal Orissa to south India.

 EXPORT OF BULK MATERIAL

 Iron ore from Ports like Vishakapattanum , Mangalore, Goa,
Paradip , Chennai Etc.
 Thermal coal from Ports Like Haldia, Kolkata,Paradip.

4
 CONCEPT OF BULK MATERIAL HANDLING IN PORTS

 Receipt of Coal
 Unloading
 Conveying
 Crushing & Screens
 Stacking & Reclaiming
 Bunkering
 General ( Auxiliary Systems, Electrical & Instrumentation and Civil & Structural).

5
SIMPLE FLOW DIAGRAM OF CHP

6
SIMPLE FLOW DIAGRAM OF CHP
TP 31 PH TP 32 TP 42
TP 43

TP 30 TRACK HOPPER
TP 41
TP 44

TP 34
TP 33 CRUSHER
TP 36
TP 35
TP 45
TP 46
TP 47 WT 1
PH
WT 2

TP 37

TP 38

TP 39

TP 40
 CONCEPT OF COAL HANDLING

 Receipt of Coal
 Trucks/dumpers
 Open Wagons Box N, Box C etc.
 Bottom discharge wagons
 Ships
 Long belt conveyors ( From Ports & Mines)

 Unloading
 Truck tipplers / Self Unloading dumpers
 Wagon tipplers / Manual unloading by opening of side doors
 Track Hopper
 Ship unloaders / Geared ship / Self unloading ships
 Surge hopper and feeders
 CONCEPT OF COAL HANDLING

 Conveying
 Feeders (Apron, Vibrating, Belt, Paddle Feeders)
 Bucket Elevators
 Steep angle conveyors
 Troughed Belt conveyors (unidirectional / Reversible)
 Shuttle Conveyors
 Pipe Conveyors
 Chutes & Skirt boards, Hoppers
 Flap gates, Rod gates, Rack & Pinion gates, Flow dividers, Shuttle heads.
 Magnetic Separators ( Inline / Cross Belt), Suspended Magnet
 Belt Weighs
 Metal Detectors
 Chute Block Switches
 Sampling system
 CONCEPT OF COAL HANDLING
 Crushers
– Ring Granulators
– Double / Four Roll crusher
– Hammer mill
– Rotary Breakers
– Feeder Breakers
 Screens
– Vibrating Screens
– Vibrating Grizzly Feeder
– Roller Screen
– Wobbler Screen
– Flip Flop Screen
– Banana Screen
 CONCEPT OF COAL HANDLING

 Stacking and Reclaiming

 Stackers (Single Boom, Twin boom)
 Reclaimed (Bucket, Bridge, Bucket on bridge, Barrel, Portal scraper)
 Stacker cum Reclaimed (Bucket Wheel)
 Undirectioned / Reversible

 Bunkering
 Motorised Tripper (Single way, Two Way & Three Way)
 Bunker Ventilation System
 Bunker sealing arrangement
 Bunker level monitors (High & Low)
 CONCEPT OF COAL HANDLING

 General

 Dust Extraction system

 Dust Suppression system (Dry Plain water, sprinklers)
 Ventilation System (Dry, wet)
 Tunnel, MCC room
 Air conditioning system
 Electrical and Mechanical hoists
 Service water , Potable water, Pneumatic System
 Electric and Instrumentation
 Civil & structural

13
REVERSIBLE STACKER CUM RECLAIMER
WAGON TIPPLER & SIDEARM CHARGER

15
PADDLE FEEDER

16
RING GRANULATOR CRUSHER

17
CONVEYING SYSTEM

18
GA OF WAGON TIPPLER COMPLEX
GA OF TRACK HOPPER COMPLEX
 COAL PRODUCTION IN INDIA

 1900 – 6.12 MT

 1920 – 18 MT

 1942 – 29 MT

 1946 – 30 MT

 33 MT – Beg. Of 1St 5 year plan

 Now approx. 400 MT/annum

21
 UN LOADING FACILITY - CHP
• 1950’s-60’s – Plant 37 MW max emerged
 Unloading – Over ground hopper (Truck tippling)

• 1960’s-70’s – Plant of 120 MW max emerged

 Unloading – Wagon tippler complex(12-15 Tips/H)

• 1970’s-80’s – Plant of 210 MW max came with pit head concept

 Unloading – Through Track hopper, wagon owned by power plant

• Early 90’s Railways started supplying Wagons

 Opted to have both Track hopper & Wagon tippler (20 tips/hr)

• After 2000 – Higher Capacity plants started

 Wagon tippler (20 – 25 tips/hr) & Track hopper of higher rate emerged

• Recently government is going towards Ultra mega Power plant (4000 MW)
 Pit head or Port based unloading
 POWER GENERATION IN MAIN STATES

 Maharashtra – 14000 MW

 Gujarat – 9500 MW

 A.P – 8100 MW

 Tamil Nadu & U.P - 7000 MW

 W.B – 6500 MW

 Bihar – 1900 MW

23
 CONCEPT OF PORT
 Port is basically a Service Provider
 Comprises
 Ship Loader & Un loader
 Conveyor
 Stacker, Reclaimer or Stacker cum Reclaimer
 Wagon Loaders, Flood loading system.

 Lower loading & unloading rates leads high penalty

 Unloading & loading rate is typically higher in ports

GEARED SHIP
MOBILE HOPPER

25
SHIP UNLOADER

26
WAGON LOADER

27
UNIDIRECTIONAL STACKER CUM RECLAIMER

28
29