COAL HANDLING SYSTEM FFBL POWER COMPANY LTD. Presented by : Muhammad Saqib Javed Khan Management Associate Solid Handling-Construction

Vendor for Coal Handling System: NORTHERN HEAVY INDUSTRIES, CHINA

CONTENTS OBJECTIVE BRIEF SUMMARY WEIGH BRIDGES COAL UNLOADING STATION COAL STORAGE YARD EMERGENCY RECLAIMING HOPPER CRUSHER HOUSE BOILER FEEDING EQUIPMENT BELT CONVEYOR SYSTEM AUXILIARY EQUIPMENT STATUS OF CONSTRUCTION ACTIVITIES

OBJECTIVE Overview of the Coal Handling System and Brief Summary of the Status of its Onsite Construction Activities

BRIEF SUMMARY SITE OVERVIEW: The whole system consists of following units: Weigh Bridges 03 Coal Unloading Station 01 Coal Storage Yard 01 Belt Conveyors (CT01 ~ CT10 A/B) 14 Transfer Towers (TT01 ~ TT07) 07 Crushing House 01 Coal & Sorbent Control Room Building 01 Pump House 01

BRIEF SUMMARY BATTERY LIMIT OF NHI: Start: Coal Unloading Station End: Travelling Tripper that discharges coal to Boiler Coal Bins

COAL POWER PLANT LAYOUT COAL HANDLING SYSTEM

COAL HANDLING PLANT LAYOUT Transfer Towers (07) COAL HANDLING PLANT LAYOUT Belt Conveyors (14) Crusher House C&S Control Room Building Coal Yard & Shed Weigh Bridges (03) Coal Unloading Station

BRIEF SUMMARY PROCESS OVERVIEW: The Coal Handling System (CHS) covers: System for Unloading Coal at CPP site Storage by Stacker Reclaiming by Reclaimer Crushing of Coal Conveying coal by Belt Conveyors Filling of CFB boiler bins CPP will use imported coal, suitable for steam generation, mainly from - Indonesia - South Africa

Emergency Reclaiming Hopper Reclaimer – Out of Order PROCESS FLOW DIAGRAM Weigh Bridges (03) Emergency Reclaiming Hopper Unloading Station Reclaimer – Out of Order Coal Yard & Shed Crusher House Boiler / Coal Bins

BRIEF SUMMARY DESIGN SUMMARY: Coal Handling System will be designed as follows: Unloading Station to Storage Yard: 500 T/h Storage Yard to Boiler bins: 200 T/h Emergency Reclaiming with pay loaders: 200 T/h

WEIGH BRIDGES PURPOSE: SPECIFICATIONS: To measure the amount of coal received, by weighing the trucks before and after unloading the coal. SPECIFICATIONS: Type: Pit-Mounted Weigh Bridge No. of Weigh Bridges: 03 Capacity (Each): 100T Dimensions: 20m x 03m

COAL UNLOADING STATION No. of Unloading Sub-Stations: 04 Each sub station comprises of following components: Hopper Rack and Pinion Gate Vibrating Feeder CAPACITIES: Hopper: 73 m³ Rack & Pinion Gate: 200 TPH Vibrating Feeder: 200 TPH Truck Capacity: 20T / 40T Note: Hopper has concrete body with Hardox-400 liners on the inclined plates.

COAL UNLOADING STATION Underground Truck Unloading Station Unloading Hoppers Vibrating Feeders Weighbridge

COAL STORAGE YARD COMPONENTS: Coal Storage Pile Coal Yard Shed Travelling Tripper Stacker Reclaimer

COAL STORAGE PILE SPECIFICATIONS: Pile Pattern: Trapezoidal with truncated top Length: 208 m Width: 50 m Height: 15 m Cross-Section: 428 m² Pile Capacity: 60,037 T Dust Control: Water Spray System

COAL STORAGE PILE

COAL YARD SHED DIMENSIONS: Shed Type: Lattice Grid Space Frame Structure: Linear shed by square pyramid - bolt balls assembly Material: Q235B (Carbon Steel) Structure Weight: 1,073 MT DIMENSIONS: Length: 240 m Width: 90 m Height: 35 m

COAL SHED SPACE FRAME NOTHERN HEAVY INDUSTRIES, CHINA Vendor for Coal Handling System: NOTHERN HEAVY INDUSTRIES, CHINA Sub-Vendor for Coal Storage Shed: XUZHOU ZM-BESTA HEAVY STEEL STRUCTURE CO., LTD.

COAL STORAGE YARD SHED TRAVELLING TRIPPER STACKER RECLAIMER COAL YARD SHED

TRAVELLING TRIPPER PURPOSE: SPECIFICATIONS: Transfer the material to the boom of Stacker SPECIFICATIONS: Belt Conveyor Width: 1,200 mm Tripper Angle: 16° Groove Angle: 30° Belt Speed: 2 m/s Total Length: ~34.5 m Rail Span: 6,000 mm

TRAVELLING TRIPPER

STACKER PURPOSE: SPECIFICATIONS: Stack the bulk material i.e. coal on to a storage pile SPECIFICATIONS: Type: Slewing Boom Stacker Stacking Capacity: 500 TPH Slewing Angle: -80° to +55° Slewing Speed: 7~20 m/min Luffing Angle: -11° to +11° Luffing Speed: 6 m/min Boom Length: 36 m

STACKER STACKER TRAVELLING TRIPPER

RECLAIMER PURPOSE: SPECIFICATIONS: Reclaim the material from storage pile by means of scrapper. Portal frame is used to support the scrapper reclaimer. SPECIFICATIONS: Type: Portal Scraper Reclaimer Reclaiming Capacity: 200 TPH No load speed: 10 m/min Boom Inclination: 0°/37°/ (min/max) Working Speed: 2.1 m/min Boom Length : (30.87+17.955) m

RECLAIMER PORTAL FRAME SECONDARY SCRAPPER PRIMARY SCRAPPER

EMERGENCY RECLAIMING Emergency Reclaiming Hopper PURPOSE: Carry out reclaiming process by means of pay loader, in any emergency situation SPECIFICATIONS: Hopper Material: Steel (Hardox liner) Capacity: 15 m³ Height: 3.7 m

CRUSHER HOUSE SPECIFICATIONS: Crusher Type: Hammer Mill (SANDVIK) Crushing Capacity: 220 TPH Screen Capacity: 220 TPH Moisture: 30 % CH Type/ Height: Enclosed / 25 m Particle Size at entrance: ≤75mm Particle Size at exit: ≤ 08 mm

BOILER FEEDING EQUIPMENT PURPOSE: Boiler coal bin provides a temporary storage of coal for the boiler. SPECIFICATIONS: No. of Tripper Cars: 02 No. of Flap Gates: 02 No. of Coal Bins: 04 Tripper Car Capacity: 200 TPH Flap Gates Capacity: 200 TPH Consumption of Coal: 1522 TPD

BOILER FEEDING EQUIPMENT Moveable Tripper Boiler 1 Coal Bin Boiler 2 Coal Bin Back

BELT CONVEYOR SYSTEM It comprises of following: Carrying Idlers Return Idlers Self aligning Idlers Pulleys Belt Driving devices Protection Switches Transfer Towers

BELT CONVEYOR SYSTEM CARRYING IDLERS RETURN IDLERS

BELT CONVEYOR SYSTEM

BELT CONVEYOR SYSTEM SPECIFICATIONS: TITLE DESCRIPTION No. of Belt Conveyors 14 Total Conveyor Length 4194m Belt Width Range 650 mm – 1200 mm Belt Construction Type EP belt with Fire Retardant Capability No. Of Plies 3 Total Thickness of Belt 14.1 mm Belt Cover Material Grade DIN class F Maximum Belt Conveyor Inclination 16 degree Capacity from Coal Unloading to Coal Yard 500TPH Capacity from Coal Yard to Boiler 200TPH

BELT CONVEYOR SYSTEM

BELT CONVEYOR SYSTEM DIMENSIONS: Total Belt Length: 4,266 m BELT CONVEYOR NAME BELT WIDTH (mm) CENTER DISTANCE - HORIZONTAL (m) BELT LENGTH (m) TOTAL LIFT CT 01 1200 130 272 18.3 CT 02 250 532 13 CT 03 650 290 600 3.8 CT 04 122.3 265 4.7 CT 05 800 241 518 CT 06 53 115 CT 07A/B 121.6 255 20.2 CT 08A 270 25.7 CT 08B 139 288 CT 09A 118 248 22.8 CT 09B 121.5 CT 10A/B 93 200 Total Belt Length: 4,266 m Total Horizontal Conveyor Distance: 2,024 m

BELT CONVEYORS - GA DRAWING

AUXILIARY EQUIPMENT Sampler Magnetic Separator Belt Weigher Metal Detector Dust Control System Ventilation System & Drainage System Fire Fighting System Note: Their description is given on next slides

AUXILIARY EQUIPMENT SAMPLER: PURPOSE: To collect a small amount of coal, from the running belt conveyor, to check its size. LOCATION: After Crusher House

AUXILIARY EQUIPMENT MAGNETIC SEPARATOR: PURPOSE: To collect the tramp metal mixed in the bulk material from the running belt conveyor. Located over the belt conveyor. Maximum Handling weight: 10 kg

AUXILIARY EQUIPMENT BELT WEIGHER: The automatic belt weighing stations shall be of load cell type. LOCATIONS: 01 BW after unloading station 02 BW after crusher house

AUXILIARY EQUIPMENT METAL DETECTOR: Mounted downstream of the magnetic separators. The metal detectors shall be located such that the tramp metal can be easily removed after the conveyor has stopped. SPECIFICATIONS: Type: Stationary Width: 650 mm Mark System: Bright Color dropping on belt upon activation

DUST CONTROL SYSTEM Dust control system will be provided at following locations: WATER SPRAYING SYSTEM DRY FOG SYSTEM WATER FOG SYSTEM BAG-FILTER DE-DUSTING UNITS Coal Yard Stacker Unloading Station (on each Hopper) Crusher House Reclaimer Emergency Hopper Boiler Coal Bunkers Transfer Towers

DUST EXTRACTION BAG FILTER – WORKING PRINCIPLE

VENTILATION & DRAINAGE SYSTEM Drainage System will be provided at following location: Unloading Station Ventilation System will be provided at following locations: MECHANICAL VENTILATION SYSTEM NATURAL VENTILATION SYSTEM Crusher House Enclosed Conveyor Galleries Unloading Station Main Control Center MCC

Coal Unloading Station VENTILATION SYSTEM Coal Unloading Station Pent House

FIRE FIGHTING SYSTEM FIRE HYDRANTS: FIRE-SPRINKLING SYSTEM: - Set on each floor with fire-alarm. - When there is a fire, the labor push the alarm, the fire pump starts. FIRE-SPRINKLING SYSTEM: - Located in enclosed gallery. Adopts temperature sensing fire alarm - When there is a fire in the gallery, the fire alarm releases a signal, and the fire pump starts automatically. FIRE FIGHTING WATER: - Comes from fire water pump house - Water feeding points are set around the coal handling system.

CPP - CONSTRUCTION

CONSTRUCTION - STATUS Civil Activities in the following areas are in progress: Coal Unloading Station Coal Storage Yard Shed Coal & Sorbent Handling Control Room Building

COAL UNLOADING STATION C&S HANDLING CONTROL ROOM BUILDING COAL HANDLING SYSTEM COAL UNLOADING STATION COAL STORAGE YARD C&S HANDLING CONTROL ROOM BUILDING

COAL UNLOADING STATION Coal Unloading Station comprises of three sub-sections: HOPPER AREA (04 SUB-STATIONS) UNDERGROUND TUNNEL / CT-01 PENT HOUSE

COAL UNLOADING STATION HOPPER AREA: It further comprises of following parts: Base Slab with Sump Pit Concrete Walls Concrete Hoppers (04 EA) Unloading Shed Base Slab: Construction has been completed

COAL UNLOADING STATION HOPPER AREA: It further comprises of following parts: Base Slab with Sump Pit Concrete Walls Concrete Hoppers (04 EA) Unloading Shed Concrete Walls: Construction has been completed up to EL: -6.5m from the base slab.

COAL UNLOADING STATION HOPPER AREA: It further comprises of following parts: Base Slab with Sump Pit Concrete Walls Concrete Hoppers (04 EA) Unloading Shed Hoppers (04 EA): Construction to be started.

COAL UNLOADING STATION HOPPER AREA: It further comprises of following parts: Base Slab with Sump Pit Concrete Walls Concrete Hoppers (04 EA) Unloading Shed Unloading Shed: Construction of Column Footings to be started.

COAL UNLOADING STATION UNDERGROUND TUNNEL / CT-01: It further comprises of following parts: Base Slab Concrete Walls Concrete Roof Base Slab: Construction has been completed.

COAL UNLOADING STATION UNDERGROUND TUNNEL / CT-01: It further comprises of following parts: Base Slab Concrete Walls Concrete Roof Concrete Walls: Reinforcement has been started. Concrete Roof: Construction to be started.

COAL UNLOADING STATION PENT HOUSE: It further comprises of following parts: Base Slab Concrete Walls Concrete Roof Column Footings: Concrete placement for Lean has been carried out.

COAL STORAGE YARD Coal Storage Yard comprises of three sub-sections: COAL YARD SHED (Columns on Grid-A and Grid-B) STACKER (Rails on South Side of the Yard) RECLAIMER (Rails on both sides of Yard)

COAL STORAGE YARD COAL YARD SHED: It further comprises of following parts: Column Footings (62 EA) Concrete Columns (64 EA) Column Footings: Construction has been completed. Concrete Columns: Reinforcement fixing has been started.

COAL STORAGE YARD STACKER: It further comprises of following parts: Column Footings (32 EA) Concrete Columns (64 EA) Column Footings: Construction is in progress

COAL STORAGE YARD RECLAMER: It further comprises of following parts: Column Footings (66 EA) Concrete Columns (66 EA) Column Footings: Construction is in progress

C & S CONTROL ROOM BUILDING Coal & Sorbent Handling Control Room Building comprises of two sections: TRANSFORMER YARD CONTROL ROOM BUILDING

C & S CONTROL ROOM BUILDING TRANSFORMER PAD AREA: It comprises of two transformer pads: Base Slab Concrete Wall / Columns Base Slab: Construction has been completed. Walls / Columns: Reinforcement in progress.

C & S CONTROL ROOM BUILDING Column Footings (23 EA) Concrete Columns (23 EA) Plinth Beam Column Footings: Construction has been completed. Columns: Reinforcement in progress. Plinth Beam: Construction to be started.

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