Fabrication, Erection & Commissioning of an 18 TPH Coal Handling System

Fabrication, Erection & Commissioning of an 18 TPH Coal Handling System


EFM was recently tasked by a major multi-national tyre manufacturing company in India with the challenge of handling and transportation of coal as part of an expansion of their 18TPH coal handling system.

Scope of work:

  • Fabrication (at site), erection & commissioning of three new conveyor systems (BC4, BC5 & BC6) and integrating them with the newly procured boilers (Boilers 1, 2 & 3).
  • Structural improvements and strengthening to the bunkers (Bunkers I, II & III) to accommodate the three new conveyors above the bunkers respectively.
  • Installation of conveyor hood, bottom sheet and scrapers in existing conveyors to avoid coal spillage


Project Summary:

The existing system comprised of a 100m long belt conveyor (BC3) that transported coal from the crusher house to a transfer tower (TT-4) from where it was then transferred to a bunker (Bunker IV) with the help of another belt conveyor (BC7).

With the addition of three new boilers, EFM supplied, erected, and commissioned three belt conveyors (BC4, BC5 & BC6) that collected coal from the existing conveyor BC3 and transported the coal to the three bunkers (Bunkers I, II & III) below which the boilers were present. The conveyors were all equipped with necessary safety switches and sensors. The coal coming from conveyor BC3 was diverted by means of a V-Plough and with the help of a connecting chute, the coal was fed to the conveyors BC4, BC5 & BC6 to fill the respective bunkers. All the existing bunkers were strengthened to install the belt conveyors above the respective bunkers. When the coal handling plant is in operation, the filling of the bunkers would begin from bunker I to bunker IV in sequence.

Another important premise of this project was the need to mitigate and reduce possible environmental impact by containing spillages and dust effectively. The crusher houses and the respective conveyors were covered by a closed gantry with side and roof sheeting for protection against harsh weather conditions. Bottom sheets were installed below the conveyors throughout the length to avoid spillage. These sheets were made dismantlable to clear the spillages if any during maintenance. Cleaning a conveyor belt is important, thus internal and external scrapers were provided on all conveyors to avoid material carry back, reduce spillage and avoid the accumulation of material between pulleys and belt, that cause misalignment.

Furthermore, being a running plant, hot sparks or hot molten metal emanating from flame-cutting and welding activities during the erection process in the work area, could come in contact with flammable coal dust and pose serious fire and boiler explosion hazards. All steps were taken to ensure a preventive mask to avoid such hazards. Thus, the project was carried out in the most stringent standards of safety and protection regarding the work area and environment.

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