Coal Handling Plant

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 Coal Handling Plant
Objective of this presentation is to make our team aware about process of
“Coal Handling System”
at Hassyan Power Plant.

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Contents
1. Coal Handling System Flow Diagram

2. Fire risks in Coal Yard

3. Fire Fighting systems provided in Coal Yard

4. Remote Controlled Monitors - Introduction
5. Remote Controlled Monitors – Construction Details
6. Remote Controlled Monitors – Operation Philosophy

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 Coal Transhipment and Coal Handling System Flow Diagram

Coal Flow

Offshore Transshipment Area CC-3A/3B

CC-9A/9B
Coal Yard-1
TT-3
TT-4

CC-4A/4B
TT-5 CC-10A/10B
Coal Yard-2

CC-2A/2B
CC-5A/5B
Arabian Gulf Sea Crusher
House
TT-6 CC-6A/6B

CC-7A/7B
TT-2
Interface point: Transhipment process and coal
unloading process

/1 B
Plant Site

Boiler#1

Boiler#2

Boiler#3

Boiler#4
- 1A
CC

Jetty CC-0A/0B TT-7 Bunker Bay

TT-1
CC-8A/8B

Coal Ship Unloader

Ship Unloaders

Jetty Terminal

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Coal Handling Plant Specifications

Coal handling plant’s main objective is to;

• Unload coal from barges to coal yard.

• Feed coal to bunkers.

Main specification of CHP at Hassyan;

• Unloading system capacity : 1500TPH

• Bunkering system capacity : 3000TPH

• Total conveyor length : Approx. 4.5 kms from jetty to bunkers

• Major equipment’s : Ship unloaders, Stacker reclaimers, Crushers, Roller Screens, belt

conveyors etc.

• Coal Yard Capacity : 11,45,000 tons (45 days coal consumption)

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Coal Unloading System

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Coal Feeding System

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Direct Bunker Feeding System

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Roller Screen & Crusher
Roller screen is designed to allow or pass desired size of coal
i.e. <50mm and discharge oversize coal i.e. >50mm to
respective coal crusher. Screen-A & B receive coal through CC-
6A & 6B respectively. <50mm coal is allowed to pass from
screen-A & B to CC-7A & 7B respectively. >50mm coal is
discharged to Crusher-A and B by Screen-A & B respectively.

Ring hammer crusher is designed to crush oversize coal

particles up to 300mm. Coal will be transferred from CC-6A
and 6B to Roller screens-A and B respectively. Roller Screens A
and B transfers oversize coal (>50mm) to coal crusher -A and B
respectively. Coal will be crushed to <50mm size and will be
transferred to CC-7A and 7B through crusher-A and B
respectively.

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Metal Detector
Metal Detectors are used to detect metal pieces in the conveying coal to prevent damages to the processing machineries like crushers,
pulverizers, belts. The Metal Detector can detect both ferrous and non-ferrous metal pieces.
At Hassyan site 4nos metal detectors are installed at 2 locations, CC-0A/0B and CC-7A/7B.

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Dust Collection System
Dust Collector is set of equipment’s which extracts dust while coal
transfer process, filters dust from air and collects in silo, again send back
to system.
 Duct collection system consists of sub systems;
• Dust Extraction and Filtration: Air with dust passes through pipes from coal
conveyors and goes into filter bags. Air passes through filter bags, while the
dust remain inside bags. The filtered air pass through bags goes to
atmosphere through a centrifugal fan.
• De-dusting: With the filtering time going on, dust accumulated on bag grows
thicker, as a result, resistance to dust collector increases and when it reaches
a set value, the device starts de-dusting. Electromagnetic pulse valve opens
and compressed air jet through pulse bag filters. With this reverse flushing,
dust on bag filters peel off and drops into dust collector. After de-dusting
electromagnetic pulse valve closes and system restore to filtering status.
• Dust collection and discharge to conveyor: Dust from bag filters collected in
silo at bottom of dust collector and discharges to conveyor through rotary
feeder.

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Dust Suppression System
Dust suppression system is installed in all transfer towers, and dust suppression nozzles are provided at all conveyors discharge and
receiving points.
For each system two small booster pumps are provided, service water coming from service water header shall be boosted and supplied to
spray drying unit. Air from compressed air storage tank shall be supplied to spray drying unit. Dried spray water shall be distributed to
different conveyor streams.
Water distributor is provided at each conveyor discharge and receiving point. Water distributor will start spraying on conveyor.

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Travelling Tripper
Travelling Tripper is a mobile travelling trolley used to feed coal to the coal bunkers from CC-8A/B. There are two travelling trippers, one
each for CC-8A & 8B respectively.
The traveling tripper shall travel on rail above bunker throughout 4 units and 20bunkers. Travelling tripper can move in forward/ reverse
direction.

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Diverter gates
Three-way diverter gates are installed at TT-4, TT-5 and TT-7 to switch over the flow from one conveyor discharge to either conveyor in
downstream.
In Coal handling System, there are 8 set of three-way diverter gates are provided, as listed here;
• CC-3A discharge to CC-9A and CC-4A/B.
• CC-3B discharge to CC-9A and CC-4A/B.
• CC-9A discharge to CC-4A/B.
• CC-9B discharge to CC-4A/B.
• CC-4A discharge to CC-10A and CC-5A.
• CC-4B discharge to CC-10A and CC-5B.
• CC-7A discharge to CC-8A/B.
• CC-7B discharge to CC-8A/B.

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Coal Blending
• Coal blending is the process of mixing coals at site to achieve quality
Proximate Analysis UOM Range
attributes that are desirable for the coal’s intended application i.e.
steam generation in our case. The quality attributes that are most Total Moisture % a.r. 7.0 - 30.0

important in blending will differ from one mine to another. Volatile Matter % a.r. 40.0 - 48.0
• At Hassyan Clean Coal Power Plant, coal will be imported from South Ash % a.r. 2.0 - 20.0
Africa, Australia and Indonesia. DEWA has specified a range of coal Grindability --  35.0 -70.0
specifications, based on this range, Hassyan Energy has signed a long-
Net calorific value per spec kcal/kg 4,777 - 6,808
term contract for coal procurement. Supplier will supply coal from
different sources within the range specified in CSA. S Sulphur % a.r. 0.1 - 1.7
• As per PPA Schedule-17 - Fuel Specifications, range of different
N2 Nitrogen % a.r. 0.6 - 1.7
properties has been defined. Coal will be received at site within this
Fl Fluorine mg/kg <200
range and different coals will be blended at site to get desired output
to meet boiler steam generation requirements. Cl Chlorine % a.r. 0.01 - 0.2
Initial Deformation Temp
°C 1100 - 1400
(I.D.T.)

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Coal Blending
• Coal blending is the process of mixing coals at site to achieve quality attributes that are desirable for the coal’s

Route Option-1

Route Option-2 Route Option-3

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In-line Magnetic Separator
• In-line magnetic separator remove/ extract suspended iron particles from running stream on coal conveyors at transfer point of a
particular conveyor.
• In-line magnetic separator is an electromagnetic machine consists of belt conveyor, gear box, pulleys and tramp collector.
• At Hassyan site, 8 sets of In-line magnetic separators are installed at 4 locations in Coal handling System as listed below:
• TT-1, C-0A/B
• TT-2, C-1A/B
• TT-3, C-2A/B
• TT-4, C-5A/B
• The In-line magnetic separator consists of local control panel with start/ stop push button required for testing purpose, whereas
provision for remote start/ stop is also available. And both the modes LOCAL / REMOTE can be selected through selector switch.

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Auto Coal Sampler
At Hassyan site Auto Coal Sampling Units are provided at two locations to collect samples;
• As Received Coal at Jetty Conveyor CC-0A/B and
• As Fired Coal at CC-7A/B.
Auto coal sampling unit will collect coal sample from running stream of conveyor after specified interval and will transfer to screw feeder.
Raw coal from screw feeder will be crushed in crusher and required quantity of coal will be collected in sample collector at ground level.
Auto coal sample can work in either manual or auto mode. It will be operated in auto mode for all the time.

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Reclaimer
• Bucket wheel reclaimer is a large-sized and highly efficient mobile
machine for reclaiming coal from coal yards. It is a complex machine
consists of many small and big equipment’s & controls.

• The machine runs on rails at bulk material stockyard; during

reclaiming, coal stacked in yard will be reclaimed to coal belt and will
be transferred to bunkers. Reclaimer can travel throughout the yard
and coal can be reclaimed as per requirements. When reclaiming
materials, the bucket wheel will rotate to take up materials on
stockyard and then the discharging device will discharge materials
onto boom conveyor, which will then transfer materials to the center
hopper of the machine and unload them onto ground belt conveyor.

• The operator of the machine may operate in manual, semi-automatic

or local control modes.

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Stacker Reclaimer
Bucket wheel stacker cum reclaimer is a large-sized and highly efficient mobile
machine for continuous handling, loading and unloading Coal in coal yards. It is a
complex machine consists of many small and big equipment’s & controls.
The machine runs on rails at bulk material stockyard and its major functions are;
• Stacking: During stacking mode, coal unloaded from barge will be unloaded
to coal yard at specified location. Stacker reclaimer can travel throughout the
yard and coal can be stacked anywhere as per requirement. Materials are
conveyed by ground belt conveyor through tripper car to be unloaded onto
the boom conveyor, and then will be thrown onto the stockyard. By adjusting
the slewing angle and luffing angle of the machine, the material dropping
position and height are changed to form a certain shape of pile thus to meet
actual requirements.
• Reclaiming: During reclaiming mode, coal stacked in yard will be reclaimed to
coal belt and will be transferred to bunkers. Stacker reclaimer can travel
throughout the yard and coal can be reclaimed as per requirements. When
reclaiming materials, the bucket wheel will rotate to take up materials on
stockyard and then the discharging device will discharge materials onto boom
conveyor, which will then transfer materials to the center hopper of the
machine and unload them onto ground belt conveyor.
The operator of the machine may operate in manual, semi-automatic or local
control modes.

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Coal Yard
• Two indoor coal stock yards are arranged in coal handling system. There are 2 stock piles in each coal yard. The dimension of every stock
piles is 630m×48m×14.5m. The capacity of each stock pile is 285,000 tons which is based on the compacted coal density (1.2t/m3) and
slope angle of 38°. Total capacity of whole coal yard is 1,140,000 tons which is 45 days coal consumption of four (4) units in BMCR
condition with worst coal.
• One Bucket Wheel Stacker Reclaimer and one Bucket wheel Reclaimer is installed in each coal shed. 3 bulldozers are provided to push
coal, 2 road rollers are provided to compact coal, 1-wheel loader is provided to carry coal transfer activity in coal yards. All earthmoving
machines will be available in coal yard 24x7.
• If smoldering coal or hot spots in the Coal yard were detected, wheel loader will be used to remove smoldering coal from approachable
locations to maintenance area in coal yard building for further quenching and disposal and excavator shall be used to remove from
smoldering coals from higher portions of the heap for further quenching and disposal.

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Coal Yard Management

Stacking Stock Management Reclaiming

• Identification of stacking location. • Minimum 10 mtr gap between coal • Coal reclaiming as per FIFO – First In

• Stacking of coal at identified location. heaps. First Out.

• Compaction of coal every two meters • Labelling of each heap with source, • Heap clearance to be followed during

height achieved. date of stacking, GCV/Ash and stacked reclaiming.

• Maintaining trapezoidal shape of qty etc. • Coal blending from different heaps.

heap. • Daily visual inspection of each heap

for hot spots.

• Weekly thermography.

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 Thank You…!!!

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