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

3. Vendor for Coal Handling System: NORTHERN HEAVY INDUSTRIES, CHINA

4. 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

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

6. 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

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

8. COAL POWER PLANT LAYOUT
COAL HANDLING SYSTEM

9. 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

10. 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

11. 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

12. 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: T/h
Emergency Reclaiming with pay loaders: 200 T/h

13. 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

14. 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.

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

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

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

18. COAL STORAGE PILE

19. 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

20. 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.

21. COAL STORAGE YARD SHED TRAVELLING TRIPPER STACKER RECLAIMER
COAL YARD SHED

22. 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

23. TRAVELLING TRIPPER

24. STACKER PURPOSE: SPECIFICATIONS:
Stack the bulk material i.e. coal on to a storage pile
SPECIFICATIONS:
Type: Slewing Boom Stacker
Stacking Capacity: 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

25. STACKER
STACKER
TRAVELLING TRIPPER

26. 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: m/min
Boom Length : ( ) m

27. RECLAIMER
PORTAL FRAME
SECONDARY SCRAPPER
PRIMARY SCRAPPER

28. 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: m

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

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

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

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

33. BELT CONVEYOR SYSTEM
CARRYING IDLERS
RETURN IDLERS

34. BELT CONVEYOR SYSTEM

35. 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

36. BELT CONVEYOR SYSTEM

37. 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

38. BELT CONVEYORS - GA DRAWING

39. 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

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

41. 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

42. 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

43. 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: mm
Mark System: Bright Color dropping
on belt upon activation

44. 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

45. DUST EXTRACTION
BAG FILTER – WORKING PRINCIPLE

46. 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

47. Coal Unloading Station
VENTILATION SYSTEM
Coal Unloading Station
Pent House

48. 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.

49. CPP - CONSTRUCTION

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

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

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

53. 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

54. 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.

55. 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.

56. 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.

57. 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.

58. 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.

59. 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.

60. 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)

61. 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.

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

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

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

65. 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.

66. 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.

67. THANK YOU

68. QUESTIONS
ARE
WELCOMED