Coal Handling Plant

Coal Analysis
1. Proximate Analysis (% by Weight)
Sr. No. Description Design Coal
1 Design GCV (Kcal/kg.) 3400
2 Ash 42.2
3 Volatile Matter 22.2
4 Fixed Carbon 26.0
5 Moisture 9.6
6 Total 100
7 Grind ability 50

2. Ultimate Analysis (For design coal)

Sr. No. Description Design Coal%
1 Carbon 36.59
2 Hydrogen 2.65
3 Oxygen 9.15
4 Nitrogen 0.72
5 Sulphur 0.49
6 Ash 42.2
7 Moisture 8.2
8 GCV (Kcal/Kg) 3400

Coal Requirement:
2.83 million tons (9000 T/day)
No. of hrs of operation (design) – 16 Hrs. a day
Total storage of crushed coal – for 10 days.
Storage capacity – 84000 Tones.
Design capacity of coal handling system – 1200 TPH.

Coal Cycle:
Coal from wagon will be unload at WT and then will be taken to crusher house.
In crusher house their will be having vibrating screen (1W+1 SB) and two (1W+1 SB)
hammer mill type crushers. Crushed coal will be taken to coal stock yard. The reversible
stacker cum re-claimer would be rail mounted, self propelled unit with 36 M boom length
having 2700 slewing and adequate lulling provision to stack coal up to 10 M height and
reclaiming the same afterwards.
In alternator arrangement crushed coal will be taken to coal bunkers having 16 Hrs
storage capacities. Necessary belt weighting arrangement, electromechanical and capacitance
type level indicators, coal sampling units, flap gates etc would be provided.
For pollution control point of view dust extractors and dust suppression system at
different points and ventilation system for underground tunnels will be provided.
 In addition, dist extraction fans will be provided in key area of boiler bunker floor.
Pressured ventilation system with unitary air filtration will be provided for control room and
MCC buildings.
Centralized control room with Microprocessor based control system will be provided
for operation of coal handling plant. This will be located near crusher house. Expect locally
controlled equipment like dust extraction / dust suppuration / ventilation equipments sump
pumps, water distribution system etc. all other in line equipment would having provision of
remote control.

List of Major Equipment:

1) Belt Conveyors – Twin Stream conveyor line of 1200 TPH capacity.

2) Reversible stacker cum reclaimer – 1 No. of 1200 TPH capacity.
3) Vibrating Feeders – 1200 TPH capacity
4) Flap gate, rack and pinion gates etc – as per requirement.
5) In-Line – Magnetic separators – before and after crushers.
6) Vibrating Screen – 2 Nos.
7) Crushers – 2 Nos. 1200 TPH each.
8) Level indicators – Nucleonic type and capacitance type
9) Chute liners and chute supporting structure – as required.
10) Bulldozer / pay loader - One No.
11) Open yard storage capacity – 10 days coal in two stock piles of crushed coal.
12) Bearing capacity of land – 25 to 30 T/Sq M depth.

Conveyor galleries trestles, super structure of crusher house and transfer houses will be
of fabricated steal structure. Intermediate floors and roof will be of RC slab expect conveyor
galleries where AC roof and side sheeting will be provided.
The track hopper and conveyor tunnels will be of concrete box section with provision
of appropriate water proofing arrangement.

Conveyor System:
Type: Twin steam conveying system with adequate change-over facility.
Capacity : 1200 TPH
Size :- Conveyor belt 1200 mm with width 35 degree to roughing angle, synthetic fire
resistant belts, belt speed 3 m/sec. with single snub drive mechanism.
Belt design: as per IS 1891, 3 ply volcanic max. Operating belt tension not to exceed
80% of Max allowance rated tension.
Track Hopper:
Length – 210 M + Approx 15 M. This will accommodate 17 Nos. wagons.
No. of Paddle Feeders: 4 Nos. 1200 TPH design/Rated capacity. Two Nos. such
feeders on each conveying stream.
Type: Hopper mouth having provision of bottom discharge from central track, grating
350 mm Square opening size suitable for (-200 mm) 60 degree lump size side area.
Wagon Tippler :
No. :- 1 No.
Type :- Rota side type with apron feeder having box type wagons with hydraulic drive
and hydraulic wagon damping.
No. of Tippling / Hr.: 25
Marshalling Equipment: Side arm charger.
Dust control: High pressure plain water dust superstores.

Coal Crusher:-
No. 2 Nos. X 100%
Type :- Ring granulator / Hammer mill.
Capacity: 1200 TPH of feed size (-30 mm).
Out put coal size: 98% (-20 mm).
Max moisture content for which crusher in designed: 20%.
Material of cage assembly: Mn steel
Material of crusher element: Rings Mn steal IS: 2062 BHN 350, To BHN 400
suspension disc. (-40) suitably hardened.
Drive motor :- 3 PH squirrel cage Induction motor, 6.6 KV 50 c/s.

Roller screen:-
No. 2 Nos.
Type :- Rotating roller felted with crusher triangular discs.
Nominal capacity: 1200 TPH.
Maximum lump size: (-300 mm)
Screen under size: 20 mm.

Traveling Tippler :-
Type:- Motorized electrical driver with twin side discharge chute.
No: 2 No. X 100%
Capacity: 1200 TPH
Travel speed: 15 M/Min.
Trashing angle: 350
Special Future: with bunker slot sealing facility by sealing belt.

In Motion Weigh – Bridge

Capacity: 1200 TPH
No.: one bi-directional
Type : Electronic (Local cell operated) pill less type.
Type of wagons: bottom discharge and all types of Box type wagons as per Indian
railway standard.
Coal sampling unit:
Type: automatic two stages
No: one set
 Primary sample type: Sweep type / cutter type.
Secondary sample type : Vezin / moving hopper.
Sample crusher: roll/hammer mill.
Material Handled: Crushed coal
Input lump size: (-20) mm.
Size of sample particle desired : (-3) mm

Stacker Re-claimer Unit and accessories:-

Size of stack: about 150 m long, two stacks of 40 m width and 10 m height.
Coal size: (-20 mm)
Equipment: Reversible stacker cum reclaimed.
Type :- Rail mounted reversible, boom stacker with bucket wheel reclaimer, electric
driver (with reeling drum) having 2100 slewing angle and hydraulic lulling
arrangement, capacity of stacking up to 10m height having bucket wheel type reclaimer
unit in reversible how discharge.
Capacity: 1200 TPH
No. 1 No.
Dust suppression: by swindling nozzle fixed by the side piles.

Sump Pump:-
Type: Vertical Non-dog type.
No. As per Requirement
Location: Track – hopper bottom, under ground conveyor etc.

Vibrating Feeder
Type: Electromagnetic
Capacity: 1200 TPH
Max lump size allocated: 600 mm
Feeder inclination: 10
Magnetic separator:
Type: Inline DC operated electro magnetic
No.: 3 Nos.
Min Tramp iron size to be separated : 20 mm cube MS
Max Tramp iron size: 250 mm X 250 mm X 100 mm MS plate.
Max. Cast iron size: 20 Kg.
(Brake Shoe)
Operating gap: 400 mm to 500 mm.
Chutes and Hopper: Valley angle min 600 chute material MS line material SS 304.
Service water pumps: as per requirement for coal stack yard, wagon tippler and track hopper.
Cross Belt Magnetic separator:
Type: Electromagnetic
No : 2 Nos.
Weight of the heaviest Piece to be separated: 50 Kg.
Air Compressor for track :
Hopper wagons:
Capacity: As per requirement
Coal handling Control Room: 2 storied RC footing RC frame RC Slab, Brick Masonry 40 M X 10 M

Flow Diagram: - Drg. No. GID – 091 – CHP – 1501

Layout Palnt:- Drg. No. GID – 091 – CHP – 1502

1. Wagon Tippler Hopper (250 MT Capacity)

2. Type of Wagon –Rota side discharge type – 2 Nos. (WT-1,WT-2)
3. Apron Feeder AFD – 1 and AFD – 2 Located below WT- 1, WT-2 will feed the coal to
101 A and 101 B Coal conveyor.
4. Integral Weight Bridge in provided in both wagon tipplers.
5. All conveyor 101A, 101B, AFD – 1, AFD-2, WT – 1, WT – 2 are located inside tunnel.
6. 101A, 101B will feed coal to 102A, 102B, at TP-101.
7. Conveyor 102 A, 102 B, will feed coal to 103 A, 103 B, at TP – 102.
8. Conveyor 103 A, 103 B, will feed coal to riverside belt feeders RBF 101 and RBF 102
which is located in crusher house.

A) Wagon Tippler Location (Shed and Hoist)

1) Wagon Tippler control room – 1 No.
2) Side Arm Charger (SEC) – 2 Nos.
3) Wagon integral weight Bridge (IWB)
4) Dust suppurations with Dry Fog (DFS) – 2 Nos.
5) Apron feeder (AFD-1, AFD -2) – 2 Nos.
6) Dibbler feeder (DF) – 2 Nos.
7) Sump Pump (SP)
Coal Circuit
WT – 1 – Conv 102 B
WT – 2 – Conv 101 A

B) Pent House
C) TP – 102 (Hoist)
1) Conv 102 B/A – Belt Weigher – TP 102 – DFS- MFG (Motorized Flap Gate) – Conv 3A and B

D) Crusher House
1) Hoist
2) Dust Extraction (DE) – 101
3) Conv 103 A – ILMS (Inline Magnetic Separator)
- RBF 101 / 102 (Reversible belt feeders) – RGI (Rod gate)
- RPG (Rack and Pinion Gate) – Wobblers Feeder
- (WF101/102) crusher 101/102 – Conv 104A/B.

E) TP-103 Hoist, DFS

- Conv 104 A/B – MG – 105/106 – BF 107 – Conv 107 Conv 105 A/B
F) TP – 104
1) Hoist, DFS
Conv 105A/B – Fixed tippler (FT) – ½ - Conv 106A-
Traveling Tippler (TTR) – MFD – Coal Bunker (Level Switch) (LS) Capacity Bunker Level Indicator
(860 MT / Bunker 4 Nos Bunker one for each mill)
Coal Bunker House.

G) TP – 105
- 105 A/B TP 1058 – 106 B – TTR – MFD- Coal Bunker (LHS)

H) TP – 106 (Hoist)
Conv 107 – DFS – 108
Conv 112 – Conv 113

I) TP – 107 (Hoist, DFS)

- Conv – 108 – TP 107 – ILMS – Conv 109
- Conv 111 – Conv 112

J) TP – 108 (Hoist, DFS)

- Conv 109 – TP 108- Conv 110.

Drive House – 101 (Hoist)

SR (Stacker / Re-claimer) – Boom Conv – Belt Weigher (BW)

Capacity – 36000 MT X 2 = 7200 MT
DS- Dust Suppresser with plain water