INTRODUCTION TO

COAL HANDLING
PLANT
 OVERVIEW

Address : P.O. Ujjwal Nagar, Sipat, Distirct – Bilaspur,

Chhatisgarh - 495555
Telephone : (STD Code – 07752) 246501
Approved capacity : 2980 MW
Installed Capacity : 2980 MW
Location : Bilaspur, Chhatisgarh
Coal Source : Dipka Mines of South Eastern Coalfields
Water Source : RBC originating from Hasdeo Barrage
Beneficiary States : Chhastisgarh, M.P, Maharashtra,Gujarat, Goa,
Daman & Diu, Dadra & Nagar Haveli.
Unit Sizes : Stage - I: 3x 660 MW
Stage -II: 2x 500 MW
Units Commissioned: Unit - I 660 MW June 2011
Unit - II 660 MW December 2011
Unit - III 660 MW June 2012
Unit - IV 500 MW May 2007
Unit - V 500 MW August 2008
Grades of Coal
Grade Calorific Value
(In Kcal/Kg)
A Exceeding 6200
B 5600-6200
C 4940-5600
D 4200-4940
E 3360-4200
F 2400-3360
G 1300-2400

Indian Coals are generally Bituminous & Sub-bituminous Coal,

Grade is D, E &F
Type of Coal
Type GCV (Kcal/kg)

Indian Coal 2800 - 4400

Imported / 5200 - 6600

Indonesian Coal
South African Coal ~ 6000
 CHP MAINLY CONSISTS…
• TRACK HOOPER
• PADDLE FEEDER
• CONVEYER BELT
• MAGNETIC SEPRATOR
• CRUSHER HOUSE
• VGF
• TRANSFER POINTS
• STACKER
• STOCKYARD/COAL
• The function of a CHP is to receive, process, store &
feed the Coal bunkers consistently over the entire
life of the Power plant.

• Coal is received from mines in the form of lumps, the

sizes varying from 100mm to 350mm,BOBR meaning
Bogie Open Bottom Rapid discharge unloaded in
TRACK HOOPERS .
(Here it comes mainly from DEEPIKA
MINES )

TRACK
HOOPER
EQUIPMENTS

Paddle Feeder Stacker Reclaimer Conveyor System Coal Samplers

Trippers : Fixed & Pumps : Horizontal Scoop Coupling Hoists & Winches
Travelling & Vertical & Misc
Paddle
Feeder
 PADDLE FEEDER
Then this raw coal is scooped onto the
conveyer by use of PADDLE FEEDER
STAGE 1 CAPACITY =1625 TPH
STAGE 2 CAPACITY =1950 TPH
Paddle Feeder
Paddle Feeder

Conveyor
Paddle Feeder

Conveyor
Paddle Feeder

Conveyor
Paddle Feeder

Conveyor
 CONVEYER BELT…
• Now this conveyer belt moves forward and carries that
raw coal to CRUSHER HOUSE.
• In between there are equipment likes METAL
DETECTORS, SUSPENDED MAGNETS which
separates coal from METALS which is not desirable in
the production and Non-ferrous materials like stones,
shells, wood etc. are removed MANUALLY
• These belts are very strong and have steel cords
• inside.
There are Normal conveyor Idlers , they are the
supporting rollers for the conveyor belt on which the
coal
laden conveyor belt glides|~|
NYLON BELT STEEL CHORD BELT
 Conveyor System
Arrangement
HEAD PULLEY
RECEIVING
CHUTE
BELT CARRYING
SIDE

IDLERS

SNUB PULLEY
BEND
BEND PULLEY
IDLERS PULLEY
BELT RETURN DISCHARGE
TAIL PULLEY SIDE CHUTE

TAKE-UP
PULLEY

TAKE-UP
WEIGHT
SUCCEDDING
CONVEYOR
CONVEYING SYSTEM

Receiving
chute Head Pulley

g Idler
Troughin
Discharge
chute
ler
Tail Pulley Return Id

Tail bend
Pulley
Head bend Take up Pulley
Pulley
CONVEYOR SYSTEM

Impact zone
 TYPES OF IDLERS

SELF ALIGNING RETURN IDLERS

SELF ALIGNING CARRYING IDLERS

CARRYING IDLERS RETURN IDLERS

IMPACT IDLERS
 CRUSHER HOUSE….
Here coal received from track hoopers is fed to
VGF(Vibrating Gizzle Feeder) which allows 20(+) size
coal to go to crusher and not allow 20(-) coal to go to
crusher where there size is reduced to 20(-)

-Here we use Roller hammer type crusher .

STAGE 1 CAPACITY 1250 TPH STAGE 2 CAPACITY 1625 TPH
NO OF HAMMERS = 14*4 =56 NO OF HAMMERS = 19*4 =76

- And there is HT motor located over springs for rotating the rollers.
-Then all 20(-) coal is sent either to STOCKYARD or to COAL BUNKERS via
appropriate TRANSFER POINTS
through CONVEYER BELT.
Vibro Greezly
Feeder
Crusher

Breaker
Plate

Cage-bars

Belt
Feeder
CRUSHER INTERNALS
 Stacker – Reclaimer

Stacking
 Stacker – Reclaimer

Reclaiming
METHOD 1 : USING DUST SUPRESSION METHOD 2 : USING FIRE HOSE WITH METHOD 3 : USING FIRE WATER MONITOR
SPRAY NOZZLES NOZZLE

COAL STOCKPILES FIRE QUENCHING TECHNIQUES

NEW METHOD: USING MODIFIED FIRE QUENCHING NOZZLE
 COAL
BLENDING
 TO BUNKERS
Unit # 5 Unit # 4
COAL BLENDING
TP-19

NORMAL COAL

TP-25
TP-18
IMPORTED COAL
Coal
Stock S/R # 3
Pile-6

YARD CONVEYOR-29
BLENDED COAL

Conveyor – 22A/B
Imported Coal

TP-15
TP-24 TP-17 TP-10

Conveyor – 13A/B
CRUSHER
TRACK HOPPER-2
HOUSE-2
 TO BUNKERS
Unit # 5 Unit # 4
COAL BLENDING
TP-19

NORMAL COAL

TP-25
TP-18
IMPORTED COAL

Coal

S/R # 3
Stock
YARD CONVEYOR-29
Pile-5 BLENDED COAL

Conveyor – 22A/B
Imported Coal

TP-15
TP-24 TP-17 TP-10

Conveyor – 13A/B
CRUSHER
TRACK HOPPER-2
HOUSE-2
 TO BUNKERS
Unit # 5 Unit # 4
COAL BLENDING
TP-19

TP-16
TP-18 Coal
Stock
Pile-3

NORMAL COAL

YARD CONVEYOR-20
Conveyor – 22A/B

Imported Coal
IMPORTED COAL

S/R # 2
BLENDED COAL

TP-15
TP-17 TP-10

Conveyor – 13A/B
CRUSHER
TRACK HOPPER-2
HOUSE-2
 TO BUNKERS
Unit # 5 Unit # 4
COAL BLENDING
TP-19

TP-16
TP-18
Coal
Stock
Pile-4
NORMAL COAL

YARD CONVEYOR-20
Conveyor – 22A/B

Imported Coal
IMPORTED COAL

BLENDED COAL

S/R # 2
TP-17 TP-15 TP-10

Conveyor – 13A/B
CRUSHER
TRACK HOPPER-2
HOUSE-2
 TO BUNKERS
Unit # 3
COAL BLENDING
TP-12

TP-16 TP-11
Coal
Stock
Pile-3

NORMAL COAL

YARD CONVEYOR-20

Conveyor – 15A/B
Imported Coal
IMPORTED COAL

S/R # 2
BLENDED COAL

TP-15
TP-17 TP-10

Conveyor – 13A/B
CRUSHER
TRACK HOPPER-2
HOUSE-2
COAL
BLENDING TO BUNKERS
TP-4

Unit # 1, 2, 3

TP-9 TP-3
Coal
Stock
Pile-1

NORMAL COAL

YARD CONVEYOR-10

Conveyor – 4A/B
Imported Coal
IMPORTED COAL

S/R # 1
BLENDED COAL

TP-1 TP-2

CRUSHER
TRACK HOPPER-1
HOUSE-1
Conveyor – 1A/B
Travelling
Trppers
Equipment Protection:
• Conveyor Protection: In order to protect the conveyor system from
any damage
1. Emergency Push Button: To immediate and completely stop the
equipment in case of any emergency. Same as EPB a stop push button
at control desk is also provided to stop equipment in case of
emergency.
2. Pull Chord Switch: Protection switch tied with pull cord (wire), to stop the conveyor in case of
any hazard to person or equipment.
3. Belt Sway Switch: To protect the conveyor from damage if conveyor
is running side way / sway.
4. Zero Speed Switch: To stop the conveyor if its speed is below permissible (in
case of belt snap, slippage, jamming)
5. Chute Block Switch: To avoid any chute chocking / jamming.
6. Suspended Magnet: To pick any ferrous material from conveyor belt
7. Metal Detector: To detect any ferrous/non-ferrous metal pieces on
conveyor belt
8. ILMS (In Line Magnetic Separator): To pick & throw off any ferrous
metal from running conveyor belt.
THANK YOU

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