Chapter 3

Coal Handling

The chapter will cover the coal handling process, coal consumption, and selection of
proper equipment for the fluidized bed technology that will be used for the design of the power
plant.

3.1 Coal Handling

In recent years, coal fluidized bed technology has gained significant attention as a
promising solution for the efficient and clean handling of coal. This technology involves
suspending coal particles in a fluidized bed of inert material, which allows for efficient
combustion and reduced emissions of pollutants such as sulfur dioxide and nitrogen oxides.
(Jones, 2019)

The use of coal fluidized bed technology offers numerous advantages over traditional
coal handling methods. These include the ability to use a wider range of coal types, improved
fuel efficiency, and lower operating costs. In addition, the technology can also facilitate the
capture and storage of carbon dioxide emissions, making it a potentially valuable tool in efforts
to mitigate climate change." (Li, 2020)

3.2 Coal Handling Process

Coal is the primary fuel used in thermal power plants. Setting up the massive unit and
large capacity, coal demand is quite high. Coal must be processed from loading and unloading to
stockpile, which may be completed by a coal conveyor system. This system involves tens of
mechanical, ensuring that these mechanicals are operating normally, which is critical for the
system's stability. And it is a critical challenge of lowering costs, ensuring manufacturing safety,
and increasing labor productivity. (Zhao and Lin, 2011)
 The coal handling process includes several actions, ranging from loading and unloading
through stockpiling. This method can be carried out using a coal conveying system, which
consists of a significant number of mechanical components. Loading/unloading, dumping,
transporting, and other vital coal handling tasks are carried out with the assistance of different
mechanical equipment. Every industry needs to make as much money as possible and raise their
production rate by putting in the most effort for care and maintenance. And it is achievable if the
equipment is in good working order, with no failures, accidents, or waste. (Ohja, 2015)

3.3 Coal Consumption

New Zealand consumed 2,765,590 tons (short tons) of coal in the year 2016, and this
ranks them as the 55th largest consumer of coal in the world. It is worth noting that New Zealand
has set a target to reach net-zero carbon emissions by 2050, which will require a significant
reduction in their reliance on fossil fuels, including coal. The amount and cost of coal needed are
crucial considerations when it comes to coal usage for electricity generation. The specific coal
consumption, which is the amount of coal needed to produce one kilowatt-hour of electricity, can
vary greatly based on various factors such as the technology used, size, age, and operational
practices.

Power Plant Capacity:

For the mass of coal:

Ship Delivery:

The different methods of transporting coal to power plants, includes rail, truck, and barge
transport. The choice of transport mode is influenced by various factors, such as the distance
between the mine and the plant, the volume of coal being transported, and the availability of
transportation infrastructure. Rail transport is generally the most efficient and cost-effective
method for transporting large volumes of coal over long distances. However, truck transport may
be more suitable for short-distance haulage or for transporting coal to plants located in remote
areas where rail or barge transport is not available. (Jones, 2018)

The 2020 study conducted by Tan and Lim, analyzed the modes of transporting coal from
New Zealand to the Philippines. Bulk carriers were found to be the primary mode of
transportation, ferrying coal from mines situated in New Zealand's West Coast area to different
ports in the Philippines. Challenges related to bulk shipping, such as the requirement for
specialized handling equipment and the variability of coal quality, were discussed. Tan and Lim
recommended that power companies in the Philippines collaborate more closely with their New
Zealand counterparts to improve the transportation and handling of coal. A Capesize bulk carrier
is chosen to carry a one-month supply of coal which is approximately 180,000 MT of coal.

Source: Encyclopedia of Marine and Energy Technology

Figure 3.1 KOHYOHSAN Bulk Carrier

Table 3.1 Bulk Carrier Specification

 Parameters Specifications
Type of Vessel Capesize Bulk Carrier
Length 279.00 m
Breadth, moulded 45.00 m
Depth, moulded 24.10 m
Draught design 16.50 m
Deadweight design 157,322 dwt
Gross tonnage 87 493

3.4 Ship Unloader

Ship unloaders for bulk cargo transfer from ships to shores. Various types of ship
unloaders, including pneumatic, mechanical, and fluidized bed systems, were discussed with an
emphasis on designing for efficiency and cost-effectiveness. Maintenance and safety measures
were also highlighted as significant factors to ensure smooth and safe operations. Additionally,
environmental factors and regulations, such as dust emissions and noise pollution, were
emphasized as important considerations in the design and operation of ship unloaders. (Wang, et.
Al, 2021)

1. Grab-Type Ship Unloader

Grab-type ship unloaders are a type of machinery used for unloading bulk cargo
from ships. These unloaders typically consist of a bucket, a rope, and a trolley system,
and they are commonly used in ports and terminals worldwide.

The operation of grab-type ship unloaders involves the bucket being lowered into
the cargo hold of a ship and filled with bulk cargo. The bucket is then lifted and
transported along the trolley system to a designated area for unloading. Once in position,
the bucket is tilted to release the cargo, which is typically deposited onto a conveyor belt
for further transport. (Li et al. 2020)
 Source: Genma GGU Series Grab Ship Unloader
Figure 3.2 Grab Ship Unloader

2. Continuous Bucket Ladder Unloader

This contraption consists of a set of buckets that are suspended between two
strands of roller chain, which operate in a continuous loop. The author explains that this
apparatus is used to unload materials in a continuous manner and provides details on it.
The continuous bucket ladder unloader is presented as a promising and eco-
friendly solution for unloading bulk materials from ships. This technology is composed
of a chain of buckets that move along a ladder to unload cargo. Additionally, the
continuous bucket ladder unloader offers environmental benefits, including the reduction
of noise pollution and energy consumption. This technology has the potential to
significantly improve the efficiency and sustainability of the shipping industry. (Shah &
Chaudhuri, 2021)
Source: Tenova TAKRAF
Figure 3.3 Grab Ship Unloader

3. Vertical Screw Unloader

The vertical screw unloader is a type of equipment used for the efficient
unloading of bulk materials from ships. Unlike traditional grab-type ship unloaders, the
vertical screw unloader uses a vertical screw conveyor to transport the cargo from the
ship's hold to the shore. This method of unloading offers several advantages, including
improved efficiency, reduced dust emissions, and lower energy consumption. The design
and operation of the vertical screw unloader involve selecting the appropriate screw
diameter, pitch, and rotation speed based on the properties of the cargo being unloaded.
These factors are critical to ensuring that the unloader can handle the material effectively
and efficiently. (Bhatia & Mehta, 2020)

One of the significant advantages of the vertical screw unloader is its ability to
reduce dust emissions during unloading. This is achieved by enclosing the screw
conveyor, which contains the cargo, and using a dust collection system to capture any
dust generated during the unloading process. By reducing dust emissions, the vertical
screw unloader offers an eco-friendlier solution to the unloading of bulk materials.
(Bhatia & Mehta, 2020)
 Overall, this concludes that the vertical screw unloader is a viable option for
efficient and sustainable unloading of bulk materials from ships. By improving the
efficiency and sustainability of the shipping industry, the vertical screw unloader has the
potential to contribute significantly to reducing the industry's environmental impact.

Source: Screwship Unloader

Figure 3.4 Vertical Screw Unloader
"Coal handling refers to the various operations involved in the transportation, storage, and
processing of coal. These operations are critical to ensuring the efficient and safe use of coal as
an energy source." - (Ghosh, 2019)

"Fluidized bed combustion is a highly efficient method of burning coal, in which the coal is
burned in a bed of heated particles suspended in air. This method of combustion reduces
emissions of pollutants such as sulfur dioxide and nitrogen oxides, making it an attractive option
for power generation." - (Narayanan, 2018)

"The handling of coal is a complex process that requires careful planning and implementation to
ensure the safe and efficient use of this valuable resource. One promising technology for coal
combustion is fluidized bed combustion, which offers a number of advantages over traditional
combustion methods." - (Yin, 2017)

"Fluidized bed combustion is a process in which coal is burned at a high temperature in a bed of
heated particles suspended in air. This method of combustion is highly efficient, producing less
waste and emitting fewer pollutants than traditional combustion methods." - (Chen, 2016)

"Coal handling is a crucial aspect of the coal-fired power generation process, and fluidized bed
combustion is one of the most promising technologies for improving the efficiency and reducing
the environmental impact of this process." - (Wang, 2015)
REFERENCES

https://www.sciencedirect.com/science/article/pii/S1877705811052441?
ref=pdf_download&fr=RR-2&rr=7a51d2d5397e104f

https://www.worldometers.info/coal/new-zealand-coal/#:~:text=Coal%20Consumption%20in
%20New%20Zealand%201%20New%20Zealand,world%27s%20total%20consumption%20of
%201%2C139%2C471%2C430%20tons.%20More%20items