Ash handling plant issues encountered at bellary site....

1. ASH HANDLING PLANT PROBLEMS JISHNU V EMP NO-6106188 BHEL ISG

2. PREVIEW EXCESSIVE COAL PILE DUST SPECS AND TESTS TO GET BETTER COAL UNEXPECTED COSTS IN BURNING COAL CUTTING COAL MAINTENANCE OLD PIPING SYSTEM

3. 1) EXCESSIVE COAL PILE DUST Problem description: Dust from coal pile blowing out to nearby houses- coal pile is a strip which is 1000ft long and 80 ft deep- Capacity of pile is around 30K tons now My suggestions: Occasional water spraying (install permanent water sprinkler) Dead storage should have semi permanent surface protection  Use of fugitive dust control polymers  Provision for thermal expansion and contraction of coal pile

4.  Construction of concrete enclosure for coal pile  Use of chemical sprays/petroleum resin/water emulsion  Chemical crusting as dust controller Proper compacting of pile to ensure competent base for crust  2:1 slope for sides, sharp edges and ridges for piles  Tank truck with a pump that can develop enough pressure to spray all portions of stock pile  Weathering of coal piles can be prevented by latex polymer

7. Bonus penalty arrangements

9. 3) UNEXPECTED COSTS IN BURNING COAL Problem description: Excessive money invested in setting up big coal stack pile resulting in a delusion of safety. The flexibility in ash handling arrangement (ASHA) is really low My suggestions:  The only possible solution is complete rework of the philosophy

10. 4) CUTTING COAL HANDLING MAINTENANCE Problem description: Maintenance of conveyors, crushers, vibrating feeders, elevators are really expensive  Abrasion and belt wear seems to be really high  Conveyor roller bearings are to changed at a frequency of 1 in 8 days  Corrosion issues are more frequent

13. Use of impact idlers

14. Coal from coal chute should be fed at the speed of conveyor belt movement

15. In order to get rid of excessive belt sagging, idler spacing and belt tension should be appropriate. The associate calculation sheets are attached

17. 5) OLD PIPING SYSTEM Problem description: Inadequate capacity in some sections, corrosion and internal deposits, poor line supports, leaking valves and joints My suggestions: A) Stop line joint leakage B) Replace leaking valves, traps; batch repair for small valves C) Making up more hangers and supports D) Assign 1 more survey engineers

18. QUERIES

19. THANK YOU