The document discusses the design and operation of a coal handling plant (CHP) system with two stages. The CHP transports coal from mines to bunkers and maintains the correct size, quality, and quantity of coal. Stage I has a capacity of 1250 MT/hr while Stage II has a higher capacity of 1500 MT/hr. The CHP includes conveyor belts, coal crushers, bunkers, stockpiles, and transport hoppers. The document provides details on the layout, equipment specifications, coal quality parameters, and operating procedures of the multi-stage CHP system.
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4. WHY CHP IS NEEDED ?
TO TRANSPORT COAL RECEIVED
FROM MINES TO COAL BUNKER,
MAINTANING:
CORRECT SIZE: (-) 200 mm
CRUSHED TO (-) 20 mm.
CORRECT QUALITY
COAL BLENDING (1:10)
ADEQUATE QUANTITY
5. CHP CAPACITY
STAGE-II
Capacity: 1500 MT/hr
Designed Capacity: 1650 MT/hr
Belt Speed: 3 m/s
Belt width: 1400 mm
Paddle Feeder capacity: 1125
MT/hr
Crusher Capacity: 940 MT/hr.
Total No.s of belt: 20
Total belt length: 6.140 KM
Total Bunker : 20
Bunker Capacity: 1140 MT
T/H Length- 200 m
T/H Capacity: 3200 MT
STAGE-I
Rated Capacity: 1250 MT/hr
Designed Capacity: 1500 MT/Hr
Belt Speed: 3 m/s
Belt width: 1400 mm
Paddle Feeder capacity: 750
MT/hr
Crusher Capacity: 625 MT/hr.
Total No.s of belt: 29
Total belt length: 6.988 KM
Total Bunker : 16
Bunker Capacity: 800 MT
T/H Length-200 m
T/H Capacity: 2700 MT
6. CHP STOCK PILE
STAGE-I
Stockyard:
14 days@ 306 MT/Hr For 14 days
= 102800 considering angle of
repose 38属 .
Both side = 102800 X 2 = 25600
MT
Additional : 102800 MT.
Dead Stock: 12 % (Cannot be
reclaimed without mobile
equipment)
Stock Pile height 12 M
Emergence stock yard: 6000 MT
S/R :
Peak Stacking-1500 MT/Hr.
Peak Reclaming:1250 MT/Hr.
STAGE-II
Stockyard:
Length of Stock Pile: 385 m
Stock Pile height 10 M
Stock Pile Width at base: 50 m
Angle of repose 37属 .
S/R :
Peak Stacking-1500 MT/Hr.
Peak Reclaming:1500 MT/Hr.
7. GRADE OF COAL GCV
A GRADE > 6280 kcal/kg
B GRADE 5601 - 6280
C GRADE 4941 - 5600
D GRADE 4201 - 4940
E GRADE 3361 - 4200
F GRADE 2401 3360
G GRADE 1300 - 2400
8. COAL ANALYSIS
BLR DESIGNED FOR COAL QUALITY-
Moisture : 20 %
Ash : 34 %
HGI : 55
Volatile Material :22%
Gross Calorific Value : 4000 Kcal/Kg.
13. RIHAND CHP LAYOUT STAGE - III
46A
46B
37A
37B
36A
47A
38A 39A
38B 39B
40A 40B
YARD
YARD
TRACK HOPPER
CR H
34A
34B
44
35A
35B
45A 45B 33A
33B
42A
42B
31A
32A
32B
43
31B
24A
TP 14
TP 15
TP 17
TP 16
PH 1
44
TP 9
TP 9ANX TP 20
TP21
TP19
TP 18
TP 27
PH 2
W T
TP 26
A B C D E F G H J A B C D E
F G H J
UNIT-5 UNIT-6
P/P H -C
TP 23
TP 22 TP 25
TP 24
MD
SM
ILMS
ILMS
ILMS
MD
BS
S.P
BS
P/P H -A
P/P H -B
MCC 3 D
MCC 3 B
MCC 3 A
MCC 3C
25A
MCC 3E
41B
41A
36B
14. COAL CRUSHER
TRACK HOPPER CONVEYOR
DIRECT FEEDING TO BUNKER
COAL RECEIVED = COAL CONSUMPTTION
BUNKER CONVEYORS
COAL BUNKERS
15. TRACK HOPPER CONVEYOR
COAL CRUSHER
BUNKER CONVEYORS
REVERSABLE YARD CONVEYOR
R
EV. B
O
O
M
C
O
N
V.
STACKING
CON.
STACKING OPERATION
COAL RECEIVED > COAL CONSUMPTTIO
16. BUNKER CONVEYORS
COAL CRUSHER
TRACK HOPPER CONVEYOR
REVERSABLE YARD CONVEYOR
RECLAMING CONVEYOR
BUCKET
WHEEL
R
EV. B
O
O
M
C
O
N
V.
STACKING
CON.
RECLAIMING OPERATION
COAL RECEIVED <COAL CONSUMPTTION
18. PROTECTION OF CONVEYOR
BELTS
Belt Sway
Switches
Pull
Chord
Switch
Pull
Chord
Under Speed / Slip
Monitor
Speed
Monitor
SAFETY DEVICES FOR BELT CONVEYORS
20. GENERAL ARRANGEMENT OF SINGLE DRIVE CONVEYOR SYSTEM
Drive
Pulley Snub
Pulley
LT
Bend
HT
Bend
Tail
Pulley
Take
Up
Pulley
Take Up
Weight
Return Idler
Toughing
Idler
IMPACT
IDLER
RECEIVING
CHUTE
SKIRT
BOARD
21. SCRAPER
Primary Scraper or Pre scraper : For removing the
heavy residue of materials adhering to the belt
surface, on return side of
the belt. These scraper is
made up of Polyurethane
blade & inclined against the
direction of belt travel.
Primary scraper are used :
Inherent moisture in the
lumpy material exceeds 15%.
Inherent moisture in fine size
material exceeds 12%.
Material is sticky in
characteristics.
When water is added to the
material externally.
SECONDARY
SCRAPER / MAIN
SCRAPER
Snub Pulley
27. The pulley to be provided closely so as to increase the
warping angle of the driving pulley is called as snub pulley.
T1/T2 = e袖慮
, Whereas 慮= Angle of Contact, 袖 = coefficient
of friction between pulley & belt, T1= Tight side tension &
T2=slack side tension
慮 = 180尊
慮 is More than 180尊
SNUB PULLEY
T1
T2
28. TANDEM TYPE SINGLE DRIVE: ONE DRIVE SHAFT
TANDEM TYPE DRIVE: ONE SHAFT IS DIRECTLY DRIVEN &
OTHER SHAFT RECEIVES THE POWER THROUGH THE
GEAR OR CHAIN , THEREBY TWO SHAFTS ARE DRIVEN.
37. PLAIN HAMMER 18 NOS
TOOTHED HAMMER-20 NOS
CRUSHING OF MATERIAL
BY COMBINATION OF
IMPACT & ROLLING
COMPRESSION.
BREAKER
PLATE
CAGE SCREEN PLATE
TRAMP IRON CHUTE
SUSPENSION BAR
38. TECHNICAL SPECIFICATION OF CRUSHER
(STAGE-I):
TYPE: RING GRANULATOR TK 16-54B
CAPACITY: 750 MTPH
MAX COAL INPUT: 400 mm 2%
LUMP SIZE: -250 mm 98%
PRODUCT SIZE: -20 mm 98%
FEED MATERIAL: COAL
MOISTURE CONTENT: 20% MAXIMUM
COAL HARD GROOVE INDEX: 50 TO 64
ROTOR SPEED : 600 RPM
MOTOR : 560 KW X 1440 RPM
FLUID COUPLING: XR-CDR-660 NU
(ELECON MAKE)
GEAR BOX: KAN 315/ S/ SO, RATIO 2.5:1
(ELECON MAKE)
FLEXIBLE COUPLING : FC 630 (ELECON
MAKE)
MATERIAL OF CONSTRUCTION:
ROTOR SHAFT: 818 M 40 BS:
4670-1971
SUSPENSION BAR : EN 24
SCREEN PLATE: AUSTENATIC
MAGANESE PLATE GRADE-111
IS:276.
CAGE & CRUSHER FRAME:
STRUCTURAL STEEL St-42 IS 226 /
152062
FRAME LINERS: TISCRAL C-45
ROTOR DISC FRAME- TISCRAL C-
45 / En-8 CK45
HAMMER RINGS: AUSTENATIC
MAGANESE STEEL
BREAKER PLATE: AUSTENATIC
MAGANESE STEEL
39. MAXIMUM SIZE OF MATERIAL & MINIMUM BELT WIDTH (mm):
Maximum diagonal
Maximum diagonal
length of lump
length of lump
100
100 150
150 200
200 250
250 300
300 400
400 500
500
Minimum belt width
Minimum belt width 400
400 500
500 600
600 750
750 900
900 1050
1050 1200
1200
FORMULA FOR CALCULATTING CONVEYOR CAPACITY:
Q= 60 . A . . 僚
Q: Conveying capacity in t/h.
A: Loaded cross sectional area of conveying material ( m3
).
: Bulk density of conveying material ( t/m3
).
: Belt Speed (m/min)
40. POWER REQUIREMENT
ACCORDING TO JAPANESE INDUSTRIAL STANDARDS (JIS):
P=P1+P2+P3
= 0.06 . f . W. v. (L + L 0 )/367 + f. Qt . (L + L 0 )/367 賊 h Qt/ 367 KW
P: POWER REQUIRED (KW)
P1: NO LOAD POWER(KW)
P2: HORIZENTAL LOAD POWER(KW)
P3: LIFTING LOAD POWER (Given with negative sign for descending belts)
(KW)
f : Coefficient of rotational friction of idlers.
w : Weight of moving parts other than the conveying material (Kg/m)
v : Belt speed (m/min)
L : Conveyor length (Horizontal centre distance between head & tail pulley) (m)
L 0 : Corrected value of centre distance (m)
: Bulk density of conveying material ( t/m3 )
Qt : Capacity (t/hr)
Qt: Qm . Whereas Qm: Conveying volume (m3
/ h)
h: Vertical height of ascending & descending lift including height of tripper, if
any (m)
41. P1: NO LOAD POWER(KW)
= 0.06 . f . W. v. (L + L 0 )/367
The required power is not proportional to conveyor length, because abrasion loss
of pulley, skirt rubber etc. & energy loss required for bending the belt exists without
relating to conveyor length, particularly because of which conveyor length of belt
plus compensated value is experimentally proportionate to the required power.
P1: HORIZENTAL LOAD POWER(KW)
= f. Qt . (L + L 0 )/367
P3: LIFTING LOAD POWER (Given with negative sign for
descending belts) (KW)
= 賊 h Qt/ 367 KW