CHAPTER III

COAL HANDLING SYSTEM

The coal handling facility is the lifeline of a pulverized-coal plant. Modern plants
have high coal demands because of the ever-increasing sizes of turbine generator units
and the economic advantages of a single coal (fuel) handling facility serving a multi-unit
power plant. Thus, coal handling facilities have had to become more flexible, more
reliable, and capable of handling larger quantities of coal in less time than ever before
(Black & Veatch, 1996).

3.1 SYSTEM FLOW DIAGRAM

Coal Delivery

Unloading
Conveyor

Stacker

Coal Yard

Reclaimer
Conveyor

Coal Crusher
Conveyor

Pulverizer
Conveyor

Bunkering

Firing

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 Fig. 3.1 Coal Handling System Flow Diagram

Figure 3.1 provides the coal handling system diagram. The coal handling system
will be responsible for unloading, conveying, storing and processing of coal that will be
delivered to the plant. The scope of the system is from the delivery of coal up to the
pulverizer and also includes the coal consumption and storage. In order to use coal more
efficiently, the coal needs to be processed and pulverized into different sizes before
feeding into the combustion equipment.

3.2 COAL CONSUMPTION

The coal consumption of the proposed power plant defines the capacity of the coal
handling facility. The rate of coal consumption affects the amount of coal that would have
to be delivered regularly and the size of coal yard that would accommodate that amount
of coal. This parameter also affects the selection of equipment that would transfer coal
from one stage of the coal handling system to another. In addition, crushers and
pulverizers are equipment whose selection depends on the rate at which they would have
to process coal (Jassim, 2010).

Pulverized coal power plants account for about 97% of the world's coal-fired
capacity. The conventional types of this technology have an efficiency of around 35%
(Energy Technology Perspective, 2008). The determination of the rate of coal
consumption starts with the selection of steam generation unit. For a capacity of 600MW,
2 units have been used for the proposed power plant each of which has a 330MW
capacity. Using the properties of the selected coal and the design power output of the
plant, the fuel consumption can be determined. Design conditions for the computation of
the coal consumption are shown in Table 3.1.

Table 3.1 Design Condition for the Computation of Coal Consumption

Lower Heating Value of Coal [1] 29.6 MJ/kg

Power Plant Efficiency [2] (35 %)
Plant Use[3] 10%
Steam Generator Capacity [4] 330 MW
No of Units 2

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 Source: [1] Coal & Allied Industries Ltd.
[2] Energy Technology Perspective, 2008
[3] Power Plant Engineering by F. Morse, 1953
[4] Babcock & Wilcox Beijing Company Ltd., 2017

 Initial Computation: Contracted Capacity

𝑃𝑙𝑎𝑛𝑡 𝑈𝑠𝑒 = 𝐼𝑛𝑝𝑢𝑡 𝑃𝑜𝑤𝑒𝑟 (0.10)

𝑃𝑙𝑎𝑛𝑡 𝑈𝑠𝑒 = 600𝑀𝑊 (0.10)

𝑷𝒍𝒂𝒏𝒕 𝑼𝒔𝒆 = 𝟔𝟎𝑴𝑾

𝐶𝑜𝑛𝑡𝑟𝑎𝑐𝑡𝑒𝑑 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 𝐼𝑛𝑝𝑢𝑡 𝑃𝑜𝑤𝑒𝑟 + 𝑃𝑙𝑎𝑛𝑡 𝑈𝑠𝑒

𝐶𝑜𝑛𝑡𝑟𝑎𝑐𝑡𝑒𝑑 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 600𝑀𝑊 + 60𝑀𝑊

𝑪𝒐𝒏𝒕𝒓𝒂𝒄𝒕𝒆𝒅 𝑪𝒂𝒑𝒂𝒄𝒊𝒕𝒚 = 𝟔𝟔𝟎 𝑴𝑾

 Initial Computation: Power Input

Given the power plant capacity and the power plant efficiency, the power input can
be determine using the equation below.

𝑃𝑜𝑤𝑒𝑟 𝑂𝑢𝑡𝑝𝑢𝑡
𝑃𝑜𝑤𝑒𝑟 𝑃𝑙𝑎𝑛𝑡 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 =
𝑃𝑜𝑤𝑒𝑟 𝐼𝑛𝑝𝑢𝑡

𝑃𝑜𝑤𝑒𝑟 𝑂𝑢𝑡𝑝𝑢𝑡
𝑃𝑜𝑤𝑒𝑟 𝐼𝑛𝑝𝑢𝑡 =
𝑃𝑜𝑤𝑒𝑟 𝑃𝑙𝑎𝑛𝑡 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦

660 𝑀𝑊
𝑃𝑜𝑤𝑒𝑟 𝐼𝑛𝑝𝑢𝑡 =
0.35

𝑷𝒐𝒘𝒆𝒓 𝑰𝒏𝒑𝒖𝒕 = 𝟏, 𝟖𝟖𝟓. 𝟕𝟏 𝑴𝑾

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 The coal consumption of the proposed power plant can be determine using the
computed power input and the lower heating value of the selected type of coal to be used
by the plant.

 Initial Computation: Coal Consumption

𝑃𝑜𝑤𝑒𝑟 𝐼𝑛𝑝𝑢𝑡
𝐶𝑜𝑎𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 =
𝐿𝐻𝑉 𝑜𝑓 𝐶𝑜𝑎𝑙

𝑀𝐽
1,885.71
𝐶𝑜𝑎𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 = 𝑠
𝑀𝐽
29.6
𝑘𝑔

𝒌𝒈 𝑻𝒐𝒏𝒔 𝑻𝒐𝒏𝒔
𝑪𝒐𝒂𝒍 𝑪𝒐𝒏𝒔𝒖𝒎𝒑𝒕𝒊𝒐𝒏 = 𝟔𝟑. 𝟕𝟏 = 𝟐𝟐𝟗. 𝟑𝟒 = 𝟓, 𝟓𝟎𝟒. 𝟐𝟓
𝒔 𝑯𝒐𝒖𝒓 𝑫𝒂𝒚

The capacity of the coal unloading system is based on the monthly receiving
requirement and specific design criteria (Black & Veatch, 1996). The monthly coal
consumption can be computed as shown below.

𝑇𝑜𝑛𝑠 30 𝑑𝑎𝑦𝑠
𝑀𝑜𝑛𝑡ℎ𝑙𝑦 𝐶𝑜𝑎𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 = 5,504.25 ( )
𝑑𝑎𝑦 1 𝑚𝑜𝑛𝑡ℎ

𝑻𝒐𝒏𝒔
𝑴𝒐𝒏𝒕𝒉𝒍𝒚 𝑪𝒐𝒂𝒍 𝑪𝒐𝒏𝒔𝒖𝒎𝒑𝒕𝒊𝒐𝒏 = 𝟏𝟔𝟓, 𝟏𝟐𝟕. 𝟒𝟏
𝑴𝒐𝒏𝒕𝒉

For every month, 165,127.41 Metric Tons of coals are consumed in order to
produce 660MW of power. Table 3.2 provides the summary of the total amount of coal
consumption of the proposed power plant.

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 Table 3.2 Summary of Coal Consumption

Coal Consumption Total Amount Amount per Unit

Seconds 0.0637 Tons/Sec 0.0318 Tons/Sec
Hourly 229.34 Tons/Hour 114.67 Tons/Hour

Daily 5,504.25 Tons/Day 2,752.12 Tons/Day

Monthly (30 Days) 165,127.41 Tons/Month 82,563.71 Tons/Month
For 60 Days 330,254.82 Tons/60 Days 165,127.41 Tons/60 Days

3.3 COAL DELIVERY

The mode of transporting coal to the power plant is determined by the location of
the plant relative to the location of the mines. The coal from supply points is delivered by
ship or boats to power stations located near the sea, whereas coal is supplied by rail or
trucks to the power stations which are located away from sea (Raja, 2006).

Coal will be delivered from Australia by ship. The size of the coal to be delivered
is approximately 50mm. The supply of coal is assumed to be delivered for every 30 days
in order to assure that the power plant will not encounter a coal shortage. A cargo vessel
will carry the one-month supply of coal required for the power plant. Figure 3.2 shows the
type of cargo vessel used for the coal delivery.

Source: Star Bulk Carriers Corp., 2017

Fig. 3.2 Photo Showing the Cargo Vessel

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 The cargo vessel could carry a weight of approximately 175,000 tons of coal.
Maximum dimension such as length and width (beam) limit the canal locks a ship can fit
in, water depth (draft) is a limitation for canals, shallow straights or harbors and height is
a limitation in order to pass under bridges (Ambrose, 2009). The technical specification
of the selected capesize cargo vessel is show in Table 3.3.

Table 3.3 Specification of the Selected Cargo Vessel

Type Capesize Bulk Carrier

Deadweight (DWT) Up to 175,000 tons
Hold Grain Capacity Up to 197,131 m3
Overall Length 290 m
Draft 18 m

Breadth 45 m
Depth 24 m
Coal Size Approximately 50 mm
Source: Star Bulk Carriers Corp., 2017

The Deadweight Tonnage (DTW) is the measure of how much weight a ship can
carry. The DTW of the selected cargo vessel is 175,000 tons which is capable of
delivering the one-month supply of the coal to the proposed power plant. Th

e cargo vessel will deliver an exact amount of 175,000 tons of coal during every
30 days.

3.4 UNLOADING

Ship unloader is normally used for handling of bulk materials. The unloading
process for shipment type of delivered bulk materials is the process of material transfer
from the ship to the conveyor system that is directly transported towards the stacker. For
the handling of bulk materials like iron-ore, limestone and coal, there are two completely
different kinds of unloaders available: the continuous ship unloaders and the grab type
ship unloaders (Gunthner, 2010). The different types of unloaders will be discussed and
compared below.

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 A. GRAB TYPE SHIP UNLOADER

The grab type ship unloader is the traditional method to unload the bulk cargo. A
clamshell bucket is cycled in and out of the ship’s hold depending on the design
specification. The clamshell is suspended from traversing trolley and is raised and
lowered by a winch. The ship unloader incorporates a hopper that provides a metered
material flow to the pier conveyor and traverses the ship on pier-mounted rails to access
each hold (Oles, 2010).

The clamshell bucket unloader uses a bucket suspended from a set of hoisting
cables, which is opened and closed by a set of control cables. Unloading is cyclical, about
one bucketful of material every 30 to 40 s. The clamshell bucket unloader for barges
usually has a low to moderate capacity. For a complete barge, including clean-up and
barge positioning, the average unloading rate is about 50% (Black &Veatch, 1996). Figure
3.3 provides an illustration of a Grab Type Ship Unloader.

Source: ThyssenKrupp Industries, 2016

Fig. 3.3 Photo Showing the Grab Type Ship Unloader

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 B. CONTINUOUS SHIP UNLOADER

The continuous ship unloader incorporates a chain and bucket elevator system to
provide continuous unloading of the ship. The continuous ship unloader is light because
it has a compact digging element with high digging capacity and a rubber belt type
elevating conveyor with high speed. Its power consumption is also lower because
unloading can be achieved only by the rotating and tilting of vertical arm at the top of the
bottom. In addition, the dust pollution can scarcely be occurred because of airtight
construction from the digging element to the jetty transfer point (Oles, 2010).

The continuous bucket ladder unloader employs a series of buckets supported

between two strands of roller chain running in a continuous loop (digging head assembly).
The buckets are filled as they are dragged through the material in the barge and are
emptied as they pass over a discharge sprocket. The continuous bucket ladder unloader
for river barges usually has a moderate to high capacity. A moderate-capacity continuous
bucket ladder unloader has a maximum free digging rate of 5,000 tons per hour. For a
complete barge, including cleanup and barge positioning, the average unloading rate is
about 65% of the remaining coal (Black &Veatch, 1996). Figure 3.4 provides an illustration
of a Continuous Ship Unloader.

Source: ThyssenKrupp Industries, 2016

Fig. 3.4 Photo Showing the Continuous Ship Unloader

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3.4.1 UNLOADER COMPARISON

To be able to select the best type unloader for the design, different parameters
were considered such as coal dust formation, unloading rate, and the specific power
consumption. Table 3.4 shows the summary of the comparison between the different
types of unloader to be considered.

Table 3.4 Specification and Comparison of Ship Unloaders

Parameter Grab Type [1] Continuous Type [2]

Coal Dust Formation High Low

Rated Capacity 2,500 3,000 TPH

Operating Hours per Day 12 hours 12 hours

Unloading Time 66.05 hours 55.04 hours

Efficiency Up to 50 % Up to 65 %

Specific Power Consumption 0.67 kWh/tom 0.34 kWh/ton

Source: [1] Konecranes Lifting Businesses PLC, 2015

[2] HL Steel Structure Co. Ltd., 2017

3.4.2 UNLOADER SELECTION

Based on the following data provided in Table 3.4, the continuous ship unloader is
the best type of unloader to be used. Though these types of unloaders are more
expensive, the continuous ship unloading operation has less spillage and high digging
capacity. It has a higher efficiency and higher capacity for unloading material resulting to
faster discharging of coal. Table 3.5 provides the specification of the selected continuous
ship unloader.

Table 3.5 Selected Continuous Ship Unloader Specifications

Type Continuous Ship Unloader

Coal Dust Formation Low

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 Unloading Capacity 3,000 TPH

Operating Hours Per Day 12 hours

Unloading Time 55.04 hours

Efficiency 65%

Specific Power Consumption 0.34 kWh/ton

Source: HL Steel Structure Co. Ltd., 2017

 Initial Computation: Unloading Time

𝑀𝑜𝑛𝑡ℎ𝑙𝑦 𝐶𝑜𝑎𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑜𝑓 𝑃𝑙𝑎𝑛𝑡

𝑈𝑛𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑇𝑖𝑚𝑒 =
𝑈𝑛𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝐸𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡

165,127.41 𝑇𝑜𝑛𝑠 𝑜𝑓 𝐶𝑜𝑎𝑙

𝑈𝑛𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑇𝑖𝑚𝑒 =
3,000 𝑇𝑃𝐻

1 𝑑𝑎𝑦
𝑈𝑛𝑙𝑜𝑎𝑑𝑖𝑛𝑔 𝑇𝑖𝑚𝑒 = 55.04 ℎ𝑜𝑢𝑟𝑠 ( )
12 ℎ𝑜𝑢𝑟𝑠 𝑜𝑓 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛

𝑼𝒏𝒍𝒐𝒂𝒅𝒊𝒏𝒈 𝑻𝒊𝒎𝒆 = 𝟒. 𝟓𝟗 𝒅𝒂𝒚𝒔 ≈ 𝟓 𝒅𝒂𝒚𝒔

The selected continuous ship unloading equipment has an unloading capacity of

3,000 TPH. The chosen unloader uses a totally enclosed conveying system which results
to a very minimal spillage. The equipment can unload the coal supply of one month in a
minimum of 5 days depending on the situational delays.

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3.5 STACKER AND RECLAIMER

After the unloading process, the coal is then transferred to the storage area. Since
coal is delivered in a very large quantity, a systematic handling of coal such as stacking
is necessary. The stockpiling and unloading of coal are closely related functions, in that
continuous unloading operations require the simultaneous withdrawal and conveying of
the material from the unloading point to the plant storage areas. The coal will be placed
systematically in the storage area using equipment known as stacker. Then after storage,
when it is time for the coal to be used, the coal is retrieved from the storage area using
equipment known as reclaimer (Yap, 2016).

Stacker and reclaimer are large machines used in coal handling facility. The
function of a stacker is to pile the coal on to a coal yard, while the reclaimer recovers the
coal from the coal yard (Robins, 2006). There are several types of equipment that are
capable of both stockout and reclaim, it is economically advantageous to consider them
for the proposed power plant. Combined stockout-reclaim equipment includes the Bucket
Wheel Stacker-Reclaimer and the Portal Stacker-Reclaimer. The different types of
stacker-reclaimer will be discussed below.

A. BUCKET WHEEL STACKER-RECLAIMER

A bucket wheel stacker-reclaimer is used for both stockout and reclaims

operations. The stacker-reclaimer is equipped with a bucket wheel at the end of the boom
for the reclaim mode. The boom conveyor is also reversible for stockout versus reclaim.
The counter-weighted, cantilevered boom conveyor is supported on a gantry that travels
on a set of rails. The stacker-reclaimer boom is capable of a luffing motion and is utilized
in both the stockout and reclaims modes (Black & Veatch, 1996). There are two types of
bucket wheel stacker-reclaimer: the trench type and slewing type.

 TRENCH TYPE BUCKET WHEEL STACKER-RECLAIMER

The trench type machine forms a long triangular cross-sectional pile beneath. The
conveyors discharge as the machine travels. The trench type boom is normally 50ft long.
Stacking and reclaim rates usually vary from 2,000 to 4,500 tons per hour). The trench
type stacker reclaimer boom is slewed only when the machine is required to stockpile

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material on the other side of the track. The trench type machine reclaims by continuously
traveling while the boom and rotating bucket wheel remains at 90 degrees to the track.
The bucket wheel reclaims the material in benches as the boom is lowered after each set
travel distance (Black & Veatch, 1996).

Source: Power Plant Engineering by Black & Veatch, 1996

Fig. 3.5 Photo Showing the Trench Type Bucket Wheel Stacker-Reclaimer

 SLEWING TYPE BUCKET WHEEL STACKER-RECLAIMER

The slewing type bucket wheel stacker-reclaimer is typically used where large
quantities of material must be readily available, where blending grades of material is
required, or where available yard length is limited. These machines feature boom lengths
up to 67 meters and stacking and reclaiming rates up to 6,000 tons per hour for coal and
8,000 to 10,000 tons per hour for iron ore. While offering maximum flexibility, slewing type
machines also help lower the unit costs involved in the handling of bulk materials (Mesto,
2013).

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 Source: Power Plant Engineering by Black & Veatch, 1996

Fig. 3.6 Photo Showing the Slewing Type Bucket Wheel Stacker-Reclaimer

B. PORTAL STACKER-RECLAIMER

A portal stacker-reclaimer is also used for both the stockout and reclaims
operations. The boom is supported from a portal structure that spans the storage pile and
travels on a set of rails, one on either side of the pile. A long pile, with a triangular cross-
section, is formed as the portal stacker-reclaimer travels. The boom supports the chain
and scraper blade assembly that is reversible for both stockout and reclaims operations
(Black & Veatch, 1996). Stockout of the material is accomplished by the boom also being
equipped with a conveyor that elevates the material to the discharge point of the boom.
The material then free falls onto the top of the pile. The boom is raised as the pile is
formed to minimize the free fall height.

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 Source: Power Plant Engineering by Black & Veatch, 1996

Fig. 3.7 Photo Showing the Portal Stacker-Reclaimer

3.5.1 STACKER-RECLAIMER COMPARISON

The type stacker-reclaimer that a plant would use for the proposed power plant
should be of the appropriate type. Table 3.6 shows the different types of stacker-reclaimer
that have been considered and their typical stockout and reclaim capacities. The
equipment with the most ideal specification will be selected.

Table 3.6 Specification and Comparison of Different Stacker-Reclaimer

Trench Type Slewing Type Portal Stacker-

Specification
Bucket Wheel [1] Bucket Wheel [2] Reclaimer [3]
Stacking Rate 2,700 TPH 3,000 TPH 1,500 TPH
Reclaiming Rate 700 TPH 1,000 TPH 1,500 TPH
Boom Length 14 m 60 m N/A
Stacking Height 13 m 20 m 33 m
Rail Length 100 m 163 mm 58 m
Specific Power Consumption 0.32 kWh/ton 0.26 kWh/ton 0.80 kWh/ton
Source: [1] KRUPP Bucket Wheel Stacker & Reclaimer, 2016
[2] HL Steel Structure Co. Ltd, 2017
[3] Samson Material Handling Ltd, 2017

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3.5.2 STACKER-RECLAIMER SELECTION

The type of stacker-reclaimer that has been selected is the slewing type bucket
wheel stacker-reclaimer, because it has the highest stacking and reclaiming capacity of
the three types equipment considered. Figure 3.8 illustrates the selected stacker-
reclaimer to be used for the proposed power plant. Table 3.7 provides the specification
of the selected stacker-reclaimer.

Source: HL Steel Structure Co. Ltd., 2017

Fig. 3.8 Selected Slewing Type Bucket Wheel Stacker-Reclaimer

Table 3.7 Specification of Selected Slewing Type Bucket Wheel Stacker-Reclaimer

Material Handled Coal

Stacking Rate 3,000 TPH
Reclaiming Rate 1,000 TPH
Belt Width 800 – 2000 m
Boom Length 60 m
Stacking Height 20 m
Rail Length 163 m

Rail Gauge 8m
Specific Power Consumption 0.26 KWh/ton
Source: HL Steel Structure Co. Ltd., 2017

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3.6 COAL YARD

It is desirable that a sufficient supply of coal should be stored within the power
plant to avoid interruption in operation. In case the power plant is far away from the coal
mines, coal stock of 30 days requirement will be provided. In case coal is delivered by
ship, stockpile of 60 days capacity will be provided, as the reliability of shipping will be
less due to variations in the weather conditions (Ramakrishna, 2016). In designing the
coal yard, stockpiling and reclaiming system must be determined first using the selected
Stacker-Reclaimer. Table 3.8 provides the design parameters for the coal yard.

Table 3.8 Design Parameters for Coal Yard

Equipment Slewing Type Bucket Wheel Stacker-Reclaimer

Active Storage [1] Long Triangular Pile
Boom Length [1] 60 m
Stacking Height [1] 20 m
Rail Length [1] 163 m
Rail Gauge [1] 8m
Coal Density [2] 975 kg/m3

Mass of Coal per 60 days 330,254.82 tons

Source: [1] HL Steel Structure Co. Ltd., 2017
[2] Hunter Valley Coal & Allied Industries Ltd.

3.6.1 STORAGE AREA CALCULATION

The storage area for the coal-fired power plant must be able to store coal supply
for 60 days of plant operation. The calculations for the storage area are shown below.

 Initial Computation: Volume of Coal Storage

1,000 𝑘𝑔
60 𝐷𝑎𝑦𝑠 𝐶𝑜𝑎𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 330,254.82 𝑡𝑜𝑛𝑠 ( 1 𝑡𝑜𝑛𝑠 )
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐶𝑜𝑎𝑙 𝑆𝑡𝑜𝑟𝑎𝑔𝑒 = =
𝐶𝑜𝑎𝑙 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑘𝑔
975 3
𝑚

𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝑪𝒐𝒂𝒍 𝑺𝒕𝒐𝒓𝒂𝒈𝒆 = 𝟑𝟑𝟖, 𝟕𝟐𝟓. 𝟗𝟕 𝒎𝟑

36 | P a g e
 Initial Computation: Volume of Each Coal Pile

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐸𝑎𝑐ℎ 𝐶𝑜𝑎𝑙 𝑃𝑖𝑙𝑒 = 𝐴𝑟𝑒𝑎 𝑇𝑟𝑖𝑎𝑛𝑔𝑙𝑒 (𝐿𝑒𝑛𝑔𝑡ℎ)

60𝑚 × 20𝑚
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐸𝑎𝑐ℎ 𝐶𝑜𝑎𝑙 𝑃𝑖𝑙𝑒 = ( ) (163𝑚)
2

𝑽𝒐𝒍𝒖𝒎𝒆 𝒐𝒇 𝑬𝒂𝒄𝒉 𝑪𝒐𝒂𝒍 𝑷𝒊𝒍𝒆 = 𝟗𝟕, 𝟖𝟎𝟎𝒎𝟑

The coal yard will have a total volume of 338,725.97 m3 and the volume of each
pile is 97,800 m3. The number of coal pile can be determined by dividing the volume of
the coal storage by the volume of the coal pile

 Initial Computation: No. of Coal Pile

338,725.97 𝑚3
𝑁𝑜. 𝑜𝑓 𝐶𝑜𝑎𝑙 𝑃𝑖𝑙𝑒 =
97,800 𝑚3

𝑵𝒐. 𝒐𝒇 𝑪𝒐𝒂𝒍 𝑷𝒊𝒍𝒆 = 𝟑. 𝟒𝟔 ≈ 𝟒 𝑷𝒊𝒍𝒆𝒔

Four coal piles are required to be able to meet the desired capacity of the proposed
power plant. Therefore, two units of stacker- reclaimer equipment will be needed for the
plant.

3.6.2 DESIGN CONSIDERATION

After computing for the dimensions of the coal pile, design considerations must be
set in order to follow right standards in the storage area of the coal. The following
considerations made are shown as follows:

 Rail gauge of 8 m are considered for the stacker-reclaimer equipment

(ThyssenKrupp Robins Inc., 2016).
 For the total area occupied by the stacker/reclaimer, the base of the Bucket Wheel
Stacker-Reclaimer has an allowance of 10 meter on both side of the stacker-
reclaimer equipment (Shandong Yuanhua International Trading, 2013). Consider
a total of 10 m allowance for the stacker/reclaimer.

37 | P a g e
  Assume an additional area of 15 m side by side allotted for roadway, and sprinkler
system. Since the operational length and width of a typical tractor (Back hoe) is
6.1m x 2m (Kubota Tractor Corporation, 2012). It is also assumed that 2 tractors
can drive to the coal yard.

Fig. 3.9 Coal Yard Layout

3.6.3 STORAGE AREA

Given the number of coal pile needed, its base width, length, space required for
the base of the stacker-reclaimer equipment and the allowance for the mobile equipment,
the area of the coal yard can be computed as follows.

 Initial Computation: Area of Coal Yard

𝐴𝑟𝑒𝑎 𝑜𝑓 𝐶𝑜𝑎𝑙 𝑌𝑎𝑟𝑑 = 𝑇𝑜𝑡𝑎𝑙 𝐿𝑒𝑛𝑔𝑡ℎ × 𝑇𝑜𝑡𝑎𝑙 𝑊𝑖𝑑𝑡ℎ

𝐴𝑟𝑒𝑎 𝑜𝑓 𝐶𝑜𝑎𝑙 𝑌𝑎𝑟𝑑 = (160 𝑚)(371 𝑚 )

𝑨𝒓𝒆𝒂 𝒐𝒇 𝑪𝒐𝒂𝒍 𝒀𝒂𝒓𝒅 = 𝟓𝟗, 𝟑𝟔𝟎 𝒎𝟐

38 | P a g e
Converting to Hectares:
1 𝐻𝑒𝑐𝑡𝑎𝑟𝑒
𝐴𝑟𝑒𝑎 𝑜𝑓 𝐶𝑜𝑎𝑙 𝑌𝑎𝑟𝑑 = 59,360 𝑚2 ( )
10,000 𝑚2

𝑨𝒓𝒆𝒂 𝒐𝒇 𝑪𝒐𝒂𝒍 𝒀𝒂𝒓𝒅 = 𝟓. 𝟗𝟑𝟔 ≈ 𝟔 𝑯𝒆𝒄𝒕𝒂𝒓𝒆𝒔

In order to accommodate the two-month supply of coal, 4 coal piles, 2 set of

stacker-reclaimer equipment and 6 hectares of land is required for the coal yard.

3.7 COAL CRUSHER

Crusher is one of the important equipment in coal handling system. Its role is to
reduce the large of sizes of coal coming from the coal yard. It is the first step to reduce
the size of coal before going to coal pulverizer that will reduce its size into fine particles.

A. JAW CRUSHER

A jaw crusher uses compressive force for breaking of particle. This mechanical
pressure is achieved by the two jaws of the crusher of which one is fixed while the other
reciprocates. A jaw or toggle crusher consists of a set of vertical jaws, one jaw is kept
stationary and is called as fixed jaw while the other jaw, called as swing jaw, moves back
and forth relative to it, by cam or pitman mechanism (Burke, 1978).

Source: Henan Liming Road & Bridge Heavy Industry Co, Ltd, 2017

Fig. 3.10 Photo Showing the Jaw Crusher

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 B. CONE CRUSHER

A cone crusher breaks rock by squeezing the rock between an eccentrically

gyrating spindle, which is covered by a wear resistant mantle, and the enclosing concave
hopper, covered by a manganese concave or a bowl liner. As rock enters the top of the
cone crusher, it becomes wedged and squeezed between the mantle and the bowl liner
or concave. Large pieces of ore are broken once, and then fall to a lower position where
they are broken again. This process continues until the pieces are small enough to fall
through the narrow opening at the bottom of the crusher (HSS, 2014).

Source: HSS-Series, 2014

Fig. 3.11 Photo Showing the Cone Crusher

C. IMPACT CRUSHER

The equipment is applicable for various coarse, medium and fine materials such
as coal, granite, limestone and concrete, etc. with grain size not exceeding 500 mm and
compression strength not higher than 360MPa. It is characterized by great reduction ratio,
high reduction efficiency and convenient maintenance. It uses plate hammer on the
rapidly rotating rotor to generate high-speed impact to crush the materials in the crushing
cavity, and casts the crushed materials along tangential direction to impact plate at the
other end of the crushing cavity (DSMAC, 2013).

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 Source: TRF Ltd, Tata Enterprise, 2015

Fig. 3.12 Photo Showing the Impact Crusher

3.7.1 COAL CRUSHER COMPARISON

The crushers that have been considered to be used in the proposed power plant
have been compared using their maximum feeding sizes, discharge sizes, and motor
power and processing capacity. Table 3.9 provides the comparison of the specification
for the considered crushers.

3.7.2 Table 3.9 Specification and Comparison of Coal Crusher

Specification Jaw Crusher [1] Cone Crusher [2] Impact Crusher [1]

Maximum Feed Size 130 mm 100 mm 120 mm

Discharge Size 40 mm 20 mm 30 mm

Capacity 30 TPH 125 TPH 60 TPH

Motor Power 25 kW 75 kW 50 kW

Specific Power
0.75 kWh/ton 0.52 kWh/ton 0.75 kWh/ton
Consumption

Source: [1] Henan Baichy Machinery Equipment Co,.Ltd

[2] Shanghai CME Machinery Co. Ltd, 2017
[3 Zhengzhou YiFan Machinery Co.,Ltd., 2017

41 | P a g e
3.7.3 COAL CRUSHER SELECTION

The crusher that has been selected for the proposed power plant is the cone
crusher. It has a small discharge size and a large capacity with low specific energy
consumption. The maximum feed size of the machine is suitable since the delivered coal
has a coal size of 50mm. The specification of the selected crusher is presented Table
3.10.

Table 3.10 Specification of Selected Coal Crusher

Type of Crusher Cone Crusher

Model CSB-160
Maximum Feed Size 100 mm
Discharge Size 20 mm
Capacity 125 TPH
Motor Power 75 Kw
Specific Power Consumption 0.52 kWh/ton
Source: Henan Liming Road & Bridge Heavy Industry Co, Ltd, 2017

Give the capacity of the selected coal crusher, the number of coal crusher unit
used for the proposed power plant can be computed as follows.

 Initial Computation: Number of Coal Crusher

𝐻𝑜𝑢𝑟𝑙𝑦 𝐶𝑜𝑎𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛/(𝑆𝐺𝑆 𝑈𝑛𝑖𝑡𝑠 𝑖𝑛 𝑡ℎ𝑒 𝑆𝑦𝑠𝑡𝑒𝑚)

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐶𝑜𝑎𝑙 𝐶𝑟𝑢𝑠ℎ𝑒𝑟 =
𝐶𝑜𝑛𝑒 𝐶𝑟𝑢ℎ𝑠𝑒𝑟 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦

229.34 𝑇𝑃𝐻/2 𝑈𝑛𝑖𝑡𝑠

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐶𝑜𝑎𝑙 𝐶𝑟𝑢𝑠ℎ𝑒𝑟 =
125 𝑇𝑃𝐻

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑪𝒐𝒂𝒍 𝑪𝒓𝒖𝒔𝒉𝒆𝒓 = 𝟎. 𝟗𝟏𝟓 ≈ 𝟏 𝑪𝒐𝒂𝒍 𝑪𝒓𝒖𝒔𝒉𝒆𝒓 𝒑𝒆𝒓 𝑺𝑮𝑺 𝑼𝒏𝒊𝒕

Based from the computation above, 2 coal crushers are needed for the system to
reduce the size of the coal into 20 mm. One extra coal crusher unit will be purchased as
a backup unit in case one fails.

42 | P a g e
3.8 PULVERIZER

The second stage of size reduction process is called Pulverizing. Coal is further
crushed in order to increase the exposure of coal particle surface with oxygen; thus
promoting rapid combustion of coal and less excess air requirement. Since the selected
combustion technology is Pulverized Coal, the coal size must be reduced to 75 µm or
0.075mm (Morse, 1953). For the selection of suitable equipment, different types of
pulverizing machine are discussed and evaluated as follows.

A. BALL MILL

Ball Mill is a size reduction equipment widely used to grind crushed materials. The
materials are grinded by rotating a cylinder with steel grinding balls, causing the ball to
fall back into the cylinder and onto the material to be ground. The rotation of the cylinder
depends upon its diameter, the larger the diameter, the slower the rotation. Ball Mills are
generally used to grind material 1/4 inch and finer, down to the particle size of 20 to 75
microns. To achieve a reasonable efficiency with ball mills, they must be operated in a
closed system, with oversize material continuously being recirculated back into the mill to
be reduced. Various classifiers, such as screens, spiral classifiers, cyclones and air
classifiers are used for classifying the discharge from ball mills.

Source: Henan Zhengzhou Mining Machinery Co. Ltd., 2015

Fig. 3.13 Photo Showing the Ball Mill

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 B. VERTICAL ROLLER MILL

Vertical roller mill is a grinding machine that process materials into extremely fine
powder. It is usually used as an efficient alternative for a ball mill. The vertical roller mill
uses a rotating drive disc to grind the materials. The main motor will drive the grinding
disc with the reducer; meanwhile hot air will enter the mill through an air inlet. Material
falls into the center of cavity from feeding hopper and move towards the edge of grinding
disc under the centrifugal force. When passing through the rollers area, large-size
material would be grinded directly by impact and compression brought by the rollers; fine
size material will form a clinker bed and be grinded. The grinded material will move
towards to edge of disc, until be taken away by heavy air flow from wind ring, the larger
powder will fall down for regrinding, qualified powder is discharged by the collector to be
the final product. On the other hand, humid materials will be dried by the hot air. Hot air
can be adjusted based upon the requirement to dry the materials.

Source: Great Wall Company, 2016

Fig. 3.14 Photo Showing the Vertical Mill

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3.8.1 PULVERIZER COMPARISON

Table 3.11 provides the specification and comparison of performance of the ball
mill and roller mill, along with their advantages and disadvantages.

Table 3.11 Specification and Comparison of Coal Pulverizer

Specification Ball Mill Vertical Mill

Feed Size ≤20 mm ≤20 mm

Discharge Size 74 – 400 µm 45 – 175 µm

Capacity 95 TPH 140 TPH

Specific Power Consumption 7.93 kWh/ton 7.14 kWh/ton

Source: Shanghai CME Machinery Co. Ltd, 2017

3.8.2 PULVERIZER SELECTION

Vertical mill is the selected pulverizer for the proposed power plant, because it has
a higher capacity of 140 TPH and a smaller power consumption of 7.14 kW/ton compared
to the ball mill pulverizer. Most importantly, the discharge size of the selected pulverizer,
which is 0.045 mm, met the desired coal size for pulverized coal-fired power plant. Table
3.12 provides the specification of the selected coal pulverizer and crusher.

Table 3.12 Specification of Selected Pulverizer and Crusher

Specification Cone Crusher [1] Vertical Mill Pulverizer [2]

Feed Size 100 mm ≤20 mm

Discharge Size 20 mm 45 – 175 µm

Capacity 125 TPH 140 TPH

Specific Power Consumption 0.52 kWh/ton 7.14 kWh/ton

Source: [1] Henan Liming Road & Bridge Heavy Industry Co, Ltd, 2017
[2] Shanghai CME Machinery Co. Ltd, 2017

45 | P a g e
3.8.3 NUMBER OF PULVERIZER

The rate of pulverized coal that leaves the pulverizer should meet the coal
consumption of the steam generator. Therefore, either a single or multiple unit of coal
pulverizer can be installed. The number of coal pulverizer depends on the coal
consumption and rated capacity of the selected equipment. The computation of the
required number of pulverizer is shown as follows.

𝐶𝑜𝑎𝑙 𝐶𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛/(𝑆𝐺𝑆 𝑈𝑛𝑖𝑡𝑠 𝑖𝑛 𝑡ℎ𝑒 𝑆𝑦𝑠𝑡𝑒𝑚)

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑃𝑢𝑙𝑣𝑒𝑟𝑖𝑧𝑒𝑟 =
𝑃𝑢𝑙𝑣𝑒𝑟𝑖𝑧𝑒𝑟 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦

229.34 𝑇𝑃𝐻/2𝑢𝑛𝑖𝑡𝑠
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑃𝑢𝑙𝑣𝑒𝑟𝑖𝑧𝑒𝑟 =
140 𝑇𝑃𝐻

𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝑷𝒖𝒍𝒗𝒆𝒓𝒊𝒛𝒆𝒓 = 𝟎. 𝟖𝟐 ≈ 𝟏 𝑷𝒖𝒍𝒗𝒆𝒓𝒊𝒛𝒆𝒓 / 𝑺𝑮𝑺 𝑼𝒏𝒊𝒕

3.9 COAL BUNKER

After crushing, live storage of coal can be provided with bunkers, coal silos and
coal bins. The word bunker is used to describe coal storage that is not part of the building
structure, but rather which is separately constructed and attached to the building structure
(Morse, 1953).

Older plants with multiple small units used a long coal bunker across all the units.
The bunkers were large-capacity, rectangular-shaped bins with multiple square hopper-
type outlets. Because of problems with hang-up of the coal on the slopes and hopper
valleys of the bunkers, steel silos are now commonly used with all sizes of units. The steel
silos are vertical cylinders, 24 to 30 ft (7.3 to 9.1 m) in diameter. They have conical outlets
and sometimes use special equal percentage decrease shaped bottom hoppers to
promote mass flow. These hoppers are constructed in sections with varying slopes such
that the rate of change in material flow area is nearly constant (Snell, 1982). The capacity
of in-plant coal silos is usually 8 to 12 h at maximum burn rate (Black & Veatch, 1996).
Table 3.13 provides the design parameters for the computation of the coal bunker
dimension.

46 | P a g e
 Table 3.13 Design Parameters for Coal Bunker

Type of Coal Bunker [1] Vertical Cylinder

Diameter [1] 7.3 – 9.1 m
Capacity [1] 8 – 12 hours
[2]
Coal Density 975 kg/m3
Total Coal Consumption 229.34 tons/hour
Source: [1] Power Plant Engineering by Black & Veatch, 1996
[2] Hunter Valley Coal & Allied Industries Ltd.

For the computation of dimensions of the coal silo, maximum capacity of 12 hours
is considered.

𝑀𝑡𝑜𝑛 1,000 𝑘𝑔
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 229.34 ( ) (12 ℎ𝑟𝑠)
ℎ𝑟 1 𝑀𝑡𝑜𝑛

𝑪𝒂𝒑𝒂𝒄𝒊𝒕𝒚 = 𝟐, 𝟕𝟓𝟐, 𝟎𝟖𝟎 𝒌𝒈

Let the volume of bunker be the same with the volume of coal that it can handle.

𝑚𝐶𝑜𝑎𝑙 2,752,080 𝑘𝑔
𝑉𝐶𝑜𝑎𝑙 = =
𝜌𝐶𝑜𝑎𝑙 kg
975 3
𝑚

𝑽𝑪𝒐𝒂𝒍 = 𝟐, 𝟖𝟐𝟐. 𝟔𝟓 𝒎𝟑

For the proposed plant, it has been considered that each pulverizer-boiler unit
should have its own live storage so that any problem with the live storage of one unit will
not affect the others. The volume of each bunker can be obtained by dividing the total
volume of coal by the number of bunkers required.

𝑇𝑜𝑡𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝐶𝑜𝑎𝑙 2,822.65 𝑚3

𝑉𝑃𝑒𝑟 𝐶𝑜𝑎𝑙 𝐵𝑢𝑛𝑘𝑒𝑟 = =
No. of Bunker 2

𝑽𝑷𝒆𝒓 𝑪𝒐𝒂𝒍 𝑩𝒖𝒏𝒌𝒆𝒓 = 𝟏, 𝟒𝟏𝟏. 𝟑𝟐 𝒎𝟑

For the diameter of the coal bunker, average value of 8.2 m is considered. Given
the diameter and volume, height of the coal bunker can be computed as follows.

47 | P a g e
 𝑑2
𝑉𝑃𝑒𝑟 𝐶𝑜𝑎𝑙 𝐵𝑢𝑛𝑘𝑒𝑟 =𝜋× ×ℎ
4

(8.2)2
1,411.32 𝑚3 = 𝜋 × ×ℎ
4

𝒉 = 𝟐𝟔. 𝟕𝟐 𝒎

Table 3.14 provides the summary of the dimensions of the coal bunker. Figure
3.15 illustrates the coal bunker with its dimensions.

Table 3.14 Dimensions of Each Coal Bunker

Diameter 8.2 m
Height 26.72 m
Total Volume of Coal 2,822.65 m3
Volume of Each Bunker 1,411.32 m3
Capacity of Each Bunker 1,376,040 kg (12 hours)

Fig. 3.15 Photo Showing the Bunker

48 | P a g e
3.10 CONVEYING SYSTEM

A conveyor system is a common piece of mechanical handling equipment that

moves materials from one location to another. Conveyors are especially useful in
application involving the transportation of heavy or bulky materials (Morse, 1953). The
type of conveying system to be used depends on the type of material and how far it needs
to be transported. For the selection of conveyors, three general types of coal conveyor
system are considered: Belt conveyor, Screw conveyor and Flight conveyor.

A. BELT CONVEYOR

In terms of long distance bulk material handling, belt conveyor system is commonly
used. Belt conveyor is a kind of machine that transfers the material continuously. The belt
works under the effect of frictional force. It is not only the component to transfer the
material but also the components to transfer the force (EMCC Mining, 2016). Belt
conveyor is composed of rollers and closed conveyor belt. There are two rollers one is
for driving conveyor rotating another one is for changing the motor direction of conveyor.
Head roller is driven by motor conveyor is dragged by force of friction which is generated
from head roller and conveyor.

Source: Henan Zhengzhou Mining Machinery Co. Ltd, 2015

Fig. 3.16 Photo Showing the Belt Conveyor

49 | P a g e
 B. SCREW CONVEYOR

The screw conveyor consists of revolving shafts with continuous or broken spiral
flighting that operates inside a casing. Powered by an electric motor and suitable gearing,
the screw conveyor usually operates in one direction only to move fine bulk material such
as meal, seed, and coal. This type of conveyor is very cost-effective and requires minimal
maintenance to operate (Design Engineering Manufacturing, 2014). Screw conveyor is a
kind of continuous conveying equipment without flexible traction mechanism. It mainly
used to convey powder, granular and small lump material which is less viscous and hard
blocking. Figure 3.17 illustrates a screw conveyor.

Source: https://sodimate-inc.com/screw-conveyor/

Fig. 3.17 Photo Showing the Screw Conveyor

50 | P a g e
 C. INCLINED BELT CONVEYOR

Inclined belt conveyors have scrapers, or flights, mounted at intervals

perpendicular to the direction of travel on endless power-driven chains operating within a
trough. Bulk materials such as sawdust, sand, gravel, coal, and chemicals may be pushed
along the trough. This coal is discharged in the bottom of trough. It is low in first cost but
has large energy consumption (Conveyor System, 2013). For conveying system that
needed an inclination larger than 30 °, flight conveyor or inclined belt conveyor is used.
Large angle belt conveyor uses corrugated sidewall belt instead of normal belt. Its
structure and working principle is same with belt conveyor, and most of its components
can be used by normal belt conveyor.

Source: Hawkmearsure, 2013

Fig. 3.18 Photo Showing the Inclined Conveyor

3.10.1 CONVEYING SYSTEM LAYOUT

For the proposed power plant, there are four conveyor system considered. These
are the conveyor system from Unloading Bay to Coal Yard (Conveyor 1), Coal Yard to
Crusher (Conveyor 2), Crusher to Pulverizer (Conveyor 3) and Pulverizer to Coal Bunker
(Conveyor 4). These conveyor systems are shown in the Figure 3.19.

51 | P a g e
 Ship Conveyor
Coal Yard
Unloader 1

Conveyor Conveyor
Crusher
3 2

Conveyor Coal
Pulverizer
4 Bunker

Fig. 3.19 Conveying System Layout

3.10.2 COVEYOR SELECTION

For the selection of conveyors, factors such as loading distance and capacity are
considered. The summary of the selected conveyor are shown in the table below.

A. SELECTED CONVEYOR FOR SHIP UNLOADER TO COAL YARD

Belt conveyor is selected for the transfer of coal from the ship unloader to the coal
yard. The selected conveyor has capacity of 1,600 to 3,200TPH. The conveyer system
can support the continuous unloading operations of the material from the unloading point
to the plant storage area. Also, it has a belt width of 1,400 mm with rated speed of 2.5 to
5m/s. Table 3.15 provides the specification of the selected conveyor.

Table 3.15 Specification of Selected Conveyor for Ship Unloader to Coal Yard

Type Belt Conveyor

Capacity 3,000 TPH
Belt Width 1,400 mm
Speed 2.5 – 5 m/s
Source: ALTA, Co., 2013

52 | P a g e
 B. SELECTED CONVEYOR FOR COAL YARD TO COAL CRUSHER

Belt conveyor is selected for the transfer of coal from the coal yard to the coal
crusher. The selected conveyor has capacity of 730 – 1,400TPH. Also, it has a belt width
of 1,200 mm with rated speed of 1 – 2 m/s. The specification of the selected conveyor is
presented in Table 4.16.

Table 3.16 Specification of Selected Conveyor for Coal Yard to Coal Crusher

Type Belt Conveyor

Capacity 1,000 TPH
Belt Width 1,200 mm
Speed 1 – 2 m/s
Source: Shanghai CME Machinery Co. Ltd, 2017

C. SELECTED CONVEYOR FOR COAL CRUSHER TO PULVERIZER

The transportation of coal from the crusher to the pulverizer requires a conveyor
that can support inclined runs. Compare to other types of conveyors, an inclined conveyor
is more appropriate because it has the ability to convey load in two directions on the upper
and lower strands. Specification of the selected conveyor is presented in Table 3.17.

Table 3.17 Specification of Selected Conveyor for Coal Crusher to Pulverizer

Type Inclined Belt Conveyor

Capacity 140 TPH
Belt Width 500 mm
Speed 2 m/s
Inclination Angle 30 Degrees
Source: Henan Zhengzhou Mining Machinery Co. Ltd, 2015

D. SELECTED CONVEYOR FOR PULVERIZER TO BUNKER

The selected conveyor for the pulverizer to the coal bunker is a flight conveyor.
The capacity of the selected conveyor is 140 TPH with a belt width of 500mm and angle
of inclination of 30 degrees. The specification of the selected inclined belt conveyor is
presented in Table 3.18.

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 Table 3.18 Specification of Selected Conveyor for Pulverizer to Coal Bunker

Type Screw Type Belt Conveyor

Capacity 140 TPH
Belt Width 500 mm
Speed 2 m/s
Inclination Angle 30 Degrees
Source: Henan Zhengzhou Mining Machinery Co. Ltd, 2015

3.10.3 SUMMARY OF SELECTED CONVEYORS

The summary of the selected conveyors for the proposed power plant is presented
in Table 3.19.

Table 3.19 Summary of Selected Conveyors

Type Selected Conveyor Capacity

Conveyor 1 Belt Conveyor 3,000 TPH
Conveyor 2 Belt Conveyor 1,000 TPH
Conveyor 3 Screw Type Conveyor 140 TPH
Conveyor 4 Screw Type Conveyor 140 TPH

3.11 COAL HANDLING SYSTEM SUMMARY

Based from the discussion above the following equipment is used for the coal
handling system.

1. A coal delivery ship with 175,000 tons capacity will deliver the monthly supply of coal
for every 30 days.
2. A continuous ship unloader with 3,000 TPH capacity will transfer the coal from the
coal ship to the unloading point. Unloading run-time of 5 days is computed based upon
the unloader’s capacity.
3. Belt conveyor with a capacity of 1,600 to 3,200 TPH will transfer the coal from the
unloading point to the coal yard.
4. Slewing type bucket wheel stacker-reclaimer with a stacking rate of 3,000 TPH and a
reclaiming rate of 1,000 TPH is selected for the stockpiling and reclaiming process.

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5. In order to accommodate the two-month supply of coal, 4 coal piles, 2 stacker-
reclaimer and 5.9 hectares of land is needed for the coal yard.
6. Belt conveyor with a capacity of 730 to 1,400 TPH will transfer the coal from the coal
yard to the crusher.
7. Two units of cone crusher with a capacity of 125 TPH are needed for the coal
processing.
8. Inclined conveyor with a capacity of 140 TPH will transfer the coal from the crusher to
the pulverizer.
9. Two units of vertical mill pulverizer with a capacity of 140 TPH are needed for the coal
processing.
10. Screw type conveyor with a capacity of 140 TPH will transfer the coal from the
pulverizer to the bunker for storage before feeding the pulverized coal to the furnace.

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Fig. 3.20 Coal Handling Flow Diagram

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