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

2. 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

3. 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)

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

5. 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

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

7. 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

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

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

10. 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

11. 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

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

13. 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

14. 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.

15. Fly & Bottom Ash Handling Plant
Fly Ash Handling Component
Fly ash 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 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

16. Layout Diagram of Ash Handling Plant
Fly Ash Handling Plant
Layout Diagram of Ash Handling Plant

17. Bottom Ash Handling Plant

18. Layout Diagram of Ash Handling Plant

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

20. 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.

21. THANK YOU