Solid Handling Systems Of FFBL Coal Power Plant Project(CPP) Project By: Saqib Iqbal Management Associate (Process)

CPP PROJECT – INTRODUCTION CPP Project AIM Alternate fuel for steam and power generation owing to shortage of Natural Gas. Meeting FFBL Steam and Power requirements Additional margins for Power Export to National grid Main Components of CPP Project 2 x 250 MeT/hr Circulating Fluidized Bed (CFB) Boilers 3 x STG’s at 60 Hz 1 x BPSTG’s or BPSTG cum Condensing at 60 Hz 1 x 55 MWe STG’s at 50 Hz for Power Export

Over-view of Flow Schematic New Coal Power Plant (CPP) Project FFBL Existing Plants Ammonia-Urea-DAP-Utilities Fertilizer’s Plant Coal (Mainly Indonesia / South Africa & local Coal) Utilities supplies to Coal Power Plant Exchange Facilities CPP Project 2 x 250 t/h CFB Boilers 3 x STGs + 01 BPSTG (60Hz) 1 x 50 ~ 60 MW (50 Hz) Balance of Plants (BOP) Limestone (Local Source) Steam supply to existing complex Sand (Local Source) Power supply to existing complex (60 Hz) Power Export to National Grid (on 50 Hz) Effluent (Storm water / Cooling tower blow down) FFBL Complex (350 Acres)

Sorbent Handling System OBJECTIVE Solid Handling System Coal Handling system Sorbent Handling System Ash Handling System Fly Ash System Bottom Ash System

Unloading at KPT / BQ Port Inland Transportation Coal Supply Chain Unloading at KPT / BQ Port Mine Site Ocean Transportation Temporary Yard at KPT Inland Transportation FFBL Plantsite

Coal Handling Plant (CHP) Layout Coal Yard Crusher House Boiler 1 Bunkers Boiler 2 Bunkers

MAIN EQUIPMENTS FOR CHP Weighing Bridges Coal Truck’s Unloading station. Magnetic Separator / Sampling Point / On-line Weighing Coal Yard (60,000 Met) Stacker ( 1 x 500 Met/hr) Re-claimer (1 x 200 Met/hr) Vibrating Feeders / Screens Conveying Belts (2 x 200 Met/hr; one line standby) Crusher House (2 x 200 Met/hr; one standby) Tripper Cars (2 x 200 Met/hr; one standby) De-dusting System Dust Suppression system

COAL TRUCKS 20 Tons Truck with hydraulic unloading system 40 Tons Truck with gates on sides for manual unloading

COAL UNLOADING STATION Covered underground unloading hoppers Ground level Coal Unloading hoppers to coal yard Conveyor belt 500 T/hr

COAL YARD Coal yard capacity is around 60,000 Met with dust suppression system Portal type stacker, 500 MeT/hr capacity with telescope discharge and dust suppression system Coal yard bypass system

STACKER & RECLAIMER Coal Pile 60,000 MeT Stacker with conveyor belt (500T/hr) Reclaimer with conveyor belt (200 T/hr) Coal Pile 60,000 MeT

BELT CONVEYOR Redundant conveying system 200 Met/hr Each line Automation through PLC Enclosed conveyor. Dust mitigation at transfer towers. Fire resistant belts

Main Equipments of Sorbent Handling Plant(SHP) Weighing Bridge (Common for Coal & Sorbent system) Sorbent Truck’s Unloading to Storage Hall Storage Silo Crushers Vibrating Feeders / Screens Conveying Belts Bucket Elevators Pneumatic Conveyor Conveying Blowers Limestone Storage Bins

Fly & Bottom Ash Handling Plant The solid matter generated after burning coal in furnace is called ash and will be generated from CFB boilers in two parts; one is Fly and other is Bottom ash. Fly ash will be collected from bag house filter and from Air Heater hopper from each boiler to prevent ash from release into environment and will be pneumatically conveyed to Fly Ash silo for disposal. Bottom ash is basically heavier and will discharge from CFB boiler furnace bottom and after cooling will be transferred to Bottom ash silo for disposal.

Fly & Bottom Ash Handling Plant Fly Ash Handling Component Fly ash generation @ 2.7 Met/hr at 150oC at BMCR per boiler for design coal. Pressurized Conveying pipes Fly Ash Silo for each boiler Silos Fluidization System Ash humidifier / conditioner for dry / wet unloading into truck. Bottom Ash Handling Component Fly ash generation @ 1.4 Met/hr at 150~230oC at BMCR per boiler for design coal. Drag Chain Conveyor up to silo Bottom Ash Silo for each boiler Ash humidifier / conditioner for dry / wet unloading into truck

Layout Diagram of Ash Handling Plant Fly Ash Handling Plant Layout Diagram of Ash Handling Plant

Bottom Ash Handling Plant

Layout Diagram of Ash Handling Plant

Bottom Ash Silo Loading Fly Ash Silo Loading Truck Ash Handling Plant Bottom Ash Silo Loading Fly Ash Silo Loading Truck

Environmental Mitigation Measures State of Art Coal, Sorbent and Ash handling system. Covered coal unloading station Bag house filter on each ash silo. Dust suppression system. Water fogging / spray system for coal handling including during coal stacking Coal yard water drainage and recovery system Enclosed conveying system. Telescopic loading of ash into trucks.

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