Coal

How Coal was Formed

Types of Coal

1 2 3

Lignite Coal Bituminous Coal Anthracite Coal

• 15% to 25% • 40% to 80% • 80% to 95%

carbon. carbon. carbon.
• Moisture • Moisture and • Very little
content over volatile volatile
35%. content (15% matter and
• LHV (5500 to to 40% ) less
14300 kJ/kg) • LHV (18800 to moisture.
29300 kJ/kg) • LHV (>30000
kJ/kg)
Thar Coal – At a Glance

Thar Coal
Coal Identified Area 9100 Sq.Km
Coal Reserves Depth 155-200 Meter
Total Estimated Coal Reserves 175 Bn Tons
Coal Seam Thickness 24 Meter
Estimated Coal Reserves in 2.0 Bn ton
Each Block
Estimated Potential of Each 4000-5000 MW for
Block 30 years
Thar Coal Characteristics
Extreme Performance Coal Range
PARAMETERS Design Coal
Extreme Values for Boiler Stable
Performance Coal Range
Operation
PROXIMATE ANALYSIS (As Received)
Total Moisture (% by weight) 49.5 44-50.2 40-55
Ash (% by weight) 7. 0 5.1-10.8 4-12
Volatile Matter (% by weight) 24.5 24.1-26 23.60-26
Fixed Carbon (% by weight) 19. 0 19.1-20.3 18.5-24
ULTIMATE ANALYSIS (As Received)
Carbon (% by weight) 30.89 27.61-37.77 27.61-37.77
Hydrogen (% by weight) 2.65 1.72-3.26 1.72-3.26
Oxygen (% by weight difference) 8.35 NA NA
Nitrogen (% by weight) 0.44 0.25-0.61 0.25-0.61
Sulfur (% by weight) 1.07 0.72-1.68 0.72-1.68
Chorine (% by weight) 0.097 0.065-0.166 0-0.166
Lower Heating Value (kJ/kg) 11198 10312-12771 9600-13400
Coal Flow

Coal yard Capacity 202,000t

To Coal (30 days)
mine •
Max coal pile height 12m
2 starker & reclaimers
• 2 bulldozers&1loder
Loaded trucks weight
From Coal Coal
2*100% devices tuck
mine sampling capacity 30t ~ 60t

Coal unloading area (7 parking)

Unloading trench capacity=1550t Empty truck • Dual way conveyor
Rotary type feeder=2 weighbridge • Disc type magnetic separator
(1*100%) • Forward capacity 600t/h
• Reverse capacity 450t/h

Transfer Transfer
Tower-1 Tower-2
Bunker house • Capacity 600t/h
• Disc type magnetic separators
• Large lump removing device Crusher house
• 1 toothed roller type crusher
capacity 450t/h
• O/L coal MAX size 50mm.
Bunker house • 1 vibrating screen
• 1 Revisable hammer type capacity
transfer tower 350 t/h Capacity 450t/h
• O/L coal max size 20mm Belt type magnetic separator
 Thar Coal Mine (SECMC)

SECMC will execute the project in three phases. The first phase of the Project is underway, in which, two 330 MW sub critical
plants will be established with majority share of Engro Powergen and is expected to be completed by 2017. In the second phase
the mine will be further expanded to 7.6 MTPA and additional 2 x 330 MW will be added which are Thar Energy Limited (1 x 330
MW) and Thalnova Power Thar(1 x 330 MW) . Subsequently in phase three the mine will be taken to its potential of 33 MTPA
capable of generating 3,960 MW.
Coal Receiving, sampling, weighing and Unloading

• Coal will be transported to the plant by truck from the coal

• Mine and the transporting time will be 10 hours per day.
• The load capacity of the truck shall be 30t to 60t.
• The coal consumption per day will be 6672.0t.
• 134 to 267 trucks will be transporting coal into the plant every day
• 14 to 27 trucks every hour. Rotary plow feeders
• The maximum size of coal from the mine shall be 350mm.
• Two heavy truck scales will be set to weigh the coal truck.
• Capacity of heavy truck weighing device is 100t.
• Two sampling device for coal sampling .
• Seven parking area for coal unloading trucks.
• Store capacity of the coal trench will be around 1550t
• Fixed gridding with the hole size of 200x200mm will be equipped on the trench.
• Two rotary plow feeders will be set on each belt conveyor
• capacity of rotary plow feeders 100-600t/h and it will be continuously adjustable
within this range.

Coal sampling device

Coal Conveyers

Controlling Mode of Coal Conveying System

A PLC system and a set of industrial TV-monitoring system will be provided for the operation of coal
handling system. The operating status of main equipment will be displayed on the LCD in control
room of coal handling.

• Disk-type magnetic separators installed in the middle of belt conveyor C-1AB.

• Belt-type magnetic separators will be installed at the head of belt conveyor C-4AB.
• Tray-type magnetic separator will be installed in the middle of belt conveyor C-3AB.
• Belt weigher installed in belt conveyor C-5AB.
• Hook type large lump removing device on C-1AB.

Disk-type magnetic separators Belt-type magnetic separators Tray-type magnetic separator

Coal Conveyers

NO Belt Name Belt Width Belt Speed Belt Capacity Belt Direction
1 C-1AB belt conveyor 1000mm 2.0m/s 600t/h One way

2 C-2AB belt conveyor 1000mm 2.0m/s 600t/h One way

3 C-3AB belt conveyor 1000mm 2.0m/s 600t/h Duel Way

4 C-4AB belt conveyor 1000mm 1.5m/s 450t/h One way

5 C-5AB belt conveyor 1000mm 1.5m/s 450t/h One way

6 C-6AB belt conveyor 1000mm 1.5m/s 450t/h One way

Transfer Towers and Dust Collectors
Transfer Tower
Transfer tower are used where coal Conveying need to change the direction or transfer coal one conveyor to an other
conveyor.

There are three transfer tower used in thar coal handling system.

• Transfer Tower #-1 between conveyor C-1AB and conveyor C-2AB

• Transfer Tower #2 between conveyor C-2A,Bconveyor C3AB, and conveyor C-4AB
• Bunker House Transfer Tower between conveyor C-5AB and conveyor C-6AB

Dust removing system

Area Device Qty Device Qty

NO.1 transfer tower Pulse Bag Dust Collector 3 Micro size water droplet dust suppression 1
system
NO.2 transfer tower Pulse Bag Dust Collector 3 Micro size water droplet dust suppression 1
system
Bunker House Transfer Pulse Bag Dust Collector 2 Micro size water droplet dust suppression 1
system
Coal Yard

• Coal yard with the length of 175m and width of 98.6m will be designed in the plant.
• The total valid capacity of coal yard will be 202,000 tons which can meet the requirement of 30 days design coal
consumption for 1x335MW unit at BMCR.
• Two stacker & reclaimers with a common track will be equipped in the permanent coal yard.
• The gyration radius of the stacker & reclaimer will be 35m.
• Stacking capacity is 600t/h and reclaiming capacity is 450t/h.
• Two bulldozers and one wheel loader will be provided for coal yard.
• Spraying facilities will be installed in the coal yard to suppress coal dust flying.
Coal Crusher

• The first-stage crusher will be toothed-roll type crusher with rated capacity of 450t/h. The inlet size shall
be no more than 350mm and the outlet size shall be less than 50mm
• The screen will be vibrating screen with a rated capacity of 450t/h
• The second-stage crusher will be revisable hammer type fine crusher having a rated capacity of 350t/h.
The inlet size shall be no more than 50mm and the outlet size shall be less than 20mm

toothed-roll type crusher

vibrating screen Reversible hammer type fine crusher
As fired Coal Sampling & Weighing

• Sampling devices which are be used to monitor the as fired coal characteristic will be installed in
the middle of belt conveyor C-5AB. It will be equipped with coal returning devices.
• Belt weighing with chain code checking device will be installed on the belt conveyor C-5AB.

Sampling devices Belt weighing device

Coal Bunkers and Feeders
After crushed, the coal with qualified size not bigger than 20mm will enter into the (6) coal bunkers by the coal
conveying belt. Then through the coal feeders and coal chutes.
The coal will be delivered to eight (8) coal feeding connections which are at the front wall of the furnace and four (4)
coal feeding connections which are at the outlet leg of the sealpots.

• (12) coal feeders

• (10)gravimetric type coal feeders.
• (2) scrape type coal feeders.
• (4) coal bunkers on front of boiler connected with 8 gravimetric type feeders
• (2) coal bunkers on rear side of boiler connected with 2 gravimetric type and 2 scrape type coal feeders.
• Both sides feeder are design 100% BMCR
• The capacity of all coal bunker are designed to be 8 Hrs coal consumption at 100% BMCR load
• The capacity of coal handling system which transports coal to the coal bunker will be more than 150% of the design
coal consumption of boiler at 100% BMCR .
• At worst coal consumption of boiler more than 135% at 100%BMCR.
Coal Bunkers and Feeders

Gravimetric coal feeder front Side Gravimetric coal feeder Rear Side
Item unit value Item unit value
Max. output t/h 50 Max. output t/h 140
Motor power kW 9 Motor power kW 18
Transmission m (about)11.8 Transmission m (about)27
distance distance
Quantity Set 8
Quantity Set 2

Scraper type coal feeder Rear Side

Item unit value
Max. output t/h 140
Motor power kW 22
Transmission m (about)21.5
distance
Quantity Set 2
Coal Consumption

No. ITEM Unit Coal Consumption

Thar coal WORST COAL
Design(coal) BMCR
CONDITION

1 Consumption/hour t/h 278 314

2 Consumption/day t/d 6672 7536

3 Consumption/year t/y 206,9988 233,8686

Losses of Coal

Potential Losses during Transportation and Storage of Coal:

As coal is transported from mine to company, it passes through different phases of loading, unloading,
transportation and storage. At each of these phases, it experience loss in Quantity and Quality (in terms of heating
value) because of several reasons. As per International Energy Agency, coal is expected to undergo a loss of 0.1 –
0.3% in Quantity and 0.05 – 0.2% in Quality (in terms of heating value)

• Transportation losses
• Oxidation losses
• Dust losses
• Coal impurities
• Self ignition losses
• Coal Moisture losses

Hazards:
• Risk to respiratory health
• Explosion
• Reduced visibility
• Slipping hazards
Fire Safety
Coal Dust Suppression Measure
• Spraying facilities will be installed in the coal yard to suppress coal dust flying.
• The dust removing system will be adopted at every transferring point to suppresscoal dust flying.
• Water clearing will be adopted in coal trestles and transfer towers.
• Closed type feed channel will be adopted on every feeding point.

Fire Devices and Safety Measures

• Safety hood, handrails, barriers or equivalent measures will be adopted around the open rotating
components.
• Fire detecting and alarm system and fire fighting system will be designed for coal handling system.
• Forced ventilation devices will be adopted in the coal unloading trench to ensure air circulation.
• Belt shall be fire retardant type.
• The coal pile height shall not exceed 12 m in the coal yard. The coal pile shall be turned at regular
intervals and stacking time of coal pile shall be reduced as much as possible.
• The hazard area shall be classified in the coal handling area according to “Explosive atmosphere”.
• All electrical and I&C equipment shall confirm to the requirement in relevant standards.