Report on

MCHP
By
Dev Shah & Archit Arya
Grasim Industries MHCP: A Self-Sufficient Powerhouse
This report delves into the intricacies of the Mechanized Coal Handling Plant (MCHP) at
Grasim Industries. As a small-scale facility, the MCHP plays a pivotal role in supplying
coal to three energy centres (EC1, EC2, and EC4) within the complex. With a combined
maximum output of approximately 100 MW and a current generation of around 50 MW,
the power plant operates as a cornerstone for the overall operations.

The MHCP’s significance extends beyond electricity generation. The plant’s efficiency,
reflected in the per-unit generation cost of 8-9 rupees, is crucial for the economic
viability of the entire Grasim complex. Furthermore, the steam produced as a byproduct
serves as a vital input for the chemical processes undertaken within the facility. In
essence, the MHCP functions as a self-sustaining energy source, providing the
necessary power and resources for the plant’s chemical and fibre production processes.

Currently, the power plant houses five boilers distributed across the three energy
centres: three in EC1, three in EC2, and two in EC4. This report will examine the coal
handling process, the equipment involved, and the operational dynamics of this critical
component of the Grasim Industries infrastructure.

Coal Yard and Initial Handling

Coal Yard

The Grasim MHCP coal yard is a substantial facility capable of storing approximately
1.25 lakh metric tonnes of coal, providing a buffer stock for nearly six months of
operations. This ample storage capacity ensures a consistent coal supply to the power
plant, mitigating potential disruptions due to supply chain challenges.
Coal Transportation
Coal is transported to the Grasim facility through two primary modes: rail and road.

Rail Transportation and Wagon Tippler

Coal arriving by rail is unloaded using a wagon tippler. This specialized equipment is
designed to efficiently overturn rail wagons to discharge their contents.

Wagon Tippler Mechanism:

1. Rail Alignment: The rail wagon is carefully positioned on the tippler tracks.
2. Clamping: Hydraulic or mechanical clamps secure the wagon to prevent
movement during the tipping process.
3. Tippling: The tippler frame is rotated, inverting the wagon to empty its contents.
4. Discharge: The discharged coal falls into a hopper or chute, leading to the
subsequent stages of the coal handling process.
5. Return: Once the wagon is empty, the tippler returns to its original position for
the next wagon.

Road Transportation and Truck Tippler

Coal transported by road is unloaded using a truck tippler. Similar to the wagon tippler, it
inverts the truck to discharge the coal.

Truck tippler Mechanism: The mechanism of a truck tippler is essentially the same as
a wagon tippler, with the primary difference being the size and weight capacity to
accommodate trucks instead of rail wagons.

Coal Flow from the tipplers

The coal discharged from both the wagon and truck tipplers typically falls into a hopper
or crusher feed bin. From there, the coal begins its journey through the coal preparation
and handling system.
Coal Yard and Initial Handling: A Deeper Look
Coal Yard and Coal Types

The Grasim MHCP coal yard serves as a crucial storage hub for the power plant's
operations. With a capacity to hold approximately 1.25 lakh metric tonnes, it ensures a
steady coal supply for nearly six months.

The coal stock at Grasim primarily consists of two types: Indian coal and international
coal. A key difference between these two varieties lies in their calorific value.

● Calorific Value: This is a measure of the heat energy released when a specific
amount of fuel is burned completely. In simpler terms, it indicates how much heat
can be generated from a unit of coal. Generally, international coal exhibits a
higher calorific value compared to Indian coal. This means that less international
coal is required to produce the same amount of heat as Indian coal.

The lower calorific value of Indian coal compared to international coal can
influence various aspects of power plant operations, including coal consumption,
combustion efficiency, and overall plant performance.

Coal Transfer from Hopper to Conveyor

Once the coal is discharged from the hopper, it is fed onto a conveyor belt by an
apron feeder. This feeder regulates the coal flow onto the belt. The conveyor belt
is the primary mode of transportation within the coal handling system, carrying
coal from one point to another.

Conveyor Belt Components and Functioning

● Belt: The core component is made up of multiple layers of plastic plies for
strength and durability. Typical widths range from 800 mm to 2200 mm,
depending on the coal handling capacity.
● Pulleys:
○ Head pulley: The driving pulley that powers the conveyor belt, typically
located at the loading end.
 ○ Tail pulley: The receiving pulley at the discharge end, maintains belt
tension.
○ Snuff pulley: An additional pulley used for specific applications, such as
cleaning the belt or controlling belt speed.
● Rollers:
○ Carrying rollers: Support the loaded side of the conveyor belt.
○ Return rollers: Support the empty side of the conveyor belt.
● Drive System:
○ Motor: Provides the power to rotate the head pulley.
○ Gearbox: Increases torque to drive the pulley at the required speed.
○ Fluid coupling: A device that transmits power smoothly between the
motor and gearbox, absorbing shock loads.

Conveyor Belt Operation

1. Coal Loading: Coal is fed onto the conveyor belt from the hopper or previous
conveyor.
2. Belt Movement: The motor drives the head pulley, propelling the belt forward.
3. Coal Transportation: The coal rides on the belt, carried by the carrying rollers.
4. Belt Return: The empty belt returns on the underside of the conveyor, supported
by the return rollers.
5. Tension Maintenance: The tail pulley and snuff pulley (if present) maintain
proper belt tension.

The conveyor belt system creates a continuous loop, efficiently transporting coal
throughout the coal handling plant. Its design and components ensure reliable
and efficient coal movement.
The Role of Transfer Points (TPs)

As you mentioned, conveyor belts often traverse through transfer points (TPs) to
change direction. These TPs are essential for routing coal to different sections of the
coal handling plant, such as storage areas, crushers, or directly to the boilers.

The Need for Crushing

Coal that arrives at the plant, especially through rail, is often in large chunks. These
large pieces are unsuitable for direct combustion in the boilers. The coal size needs to
be reduced to ensure efficient combustion and heat transfer. This is where the four-roll
crusher comes into play.

Four Roll Crusher: Working and Mechanism

A four-roll crusher consists of four heavy-duty steel rolls arranged in pairs. The coal is
fed into the crusher, where it is subjected to compressive forces between the rotating
rolls. As the coal passes through the crusher, it is progressively reduced in size.

● Crushing Action: The four rolls rotate at different speeds, creating a shearing
and compressive action on the coal.
● Product Size: The gap between the rolls can be adjusted to control the final size
of the crushed coal.
● Material Handling: The crushed coal is then typically transferred to another
conveyor belt for further processing or storage.

Key advantages of using a four-roll crusher:

● Efficient crushing: It can handle large volumes of coal with high reduction
ratios.
● Product uniformity: The crushed coal size is relatively consistent.
● Low maintenance: The simple design of the four-roll crusher reduces downtime.

By effectively reducing the coal size, the four-roll crusher plays a crucial role in
optimizing the combustion process and improving overall power plant efficiency.
Flap Gates at Transfer Points

Flap gates are crucial components at transfer points within the coal handling system.
They play a pivotal role in controlling the flow of coal and directing it to the appropriate
conveyor belt.

Flap Gate Mechanism

A flap gate is essentially a hinged, rectangular plate that can be positioned to block or
allow material passage. It is typically mounted on a frame and operated by a pneumatic
or hydraulic actuator.

● Open Position: When the flap gate is fully open, it allows the coal to flow freely
from one conveyor to another.
● Closed Position: When closed, the flap gate forms a tight seal, preventing coal
from passing through.

Flap Gate Operation

The flap gate's position is controlled by a control system that determines the desired
coal flow direction. When a change in direction is required, the actuator is activated to
open or close the flap gate accordingly.

Key functions of flap gates:

● Diverting coal flow: Directing coal to different conveyors or processing

equipment.
● Preventing backflow: Stopping the reverse flow of coal.
● Controlling coal volume: Regulating the amount of coal passing through a
particular point.

By effectively managing coal flow, flap gates contribute to the overall efficiency and
flexibility of the coal handling system
Coal Preparation: Crushing, Screening, and Blending
Crushing

As discussed earlier, the four-roll crusher is a primary equipment for reducing coal size.
After crushing, the coal might need further size reduction depending on the boiler
requirements. Other types of crushers, like hammer mills or impact crushers, can be
used for finer crushing.

Screening

To ensure uniform coal size, the crushed coal is passed through vibrating screens.
These screens are inclined and have openings of specific sizes. The oversized coal is
retained on the screen for further crushing, while the undersized coal passes through to
the next stage.

● Types of Screens: Vibrating screens, rotary screens, and grizzly feeders are
commonly used.
● Screen Mesh Size: The size of the screen openings determines the final product
size.

Blending

Blending involves mixing different types of coal to achieve desired coal characteristics,
such as calorific value, ash content, and moisture content. This process is crucial for
optimizing boiler performance and reducing emissions.

● Blending Methods: Coal from different sources or stockpiles is combined using

conveyors and blending chambers.
● Blending Ratios: The proportions of different coal types are carefully calculated
to achieve the desired coal blend.

By effectively crushing, screening, and blending the coal, the power plant can ensure
that the fuel is in the optimal condition for combustion.
Coal Storage and Reclaiming
Once the coal has undergone the necessary preparation processes, it's typically stored
in large stockpiles for future use. This storage serves multiple purposes:

● Inventory management: Ensuring a consistent coal supply to the power plant.

● Demand fluctuations: Accommodating variations in coal consumption.
● Price fluctuations: Taking advantage of market conditions.

FIFO in Stockyard Management

FIFO stands for First In, First Out. It's a stock management principle that dictates that
the oldest coal in inventory should be the first one used. In the context of a stockyard,
this means that the first batch of material brought in should be the first batch to be used.

How FIFO Works in a Stockyard

● Incoming Material: When new material arrives at the stockyard, it's typically
placed at the end of the stockpile.
● Outgoing Material: As material is needed for shipment or further processing, it's
taken from the beginning of the stockpile.
● Stock Rotation: This continuous process ensures that older material doesn't get
stuck at the back of the stockpile, preventing degradation or obsolescence,
especially for quality concerns.

Benefits of FIFO in Stockyard Management

● Reduced Waste: By prioritizing the oldest stock, the risk of product degradation
is minimized.
● Accurate Inventory Valuation: Since the cost of the oldest items is used to
calculate the cost of goods sold, the valuation of inventory is more accurate.
● Improved Cash Flow: Faster inventory turnover can lead to improved cash flow.
● Efficient Space Utilization: Regular stock movement prevents dead stock
accumulation.

Stockpile Management

To efficiently manage the coal stockpile, several key components and processes are
involved:
 ● Stacker: A machine that builds the coal pile by depositing coal from a conveyor
belt.
● Reclaimer: Equipment used to extract coal from the stockpile.
● Blending: Coal from different stockpiles can be blended to achieve desired coal
characteristics.
● Fire prevention: Implementing measures to prevent spontaneous combustion.

Reclaiming Process

Reclaiming involves retrieving coal from the stockpile and feeding it back into the coal
handling system.

● Reclaimer Types: There are various types of reclaimers, including bridge

reclaimers, bucket wheel reclaimers, and front-end loaders.
● Coal Feeding: The reclaimed coal is typically fed onto a conveyor belt for further
transportation.

Effective stockpile management is crucial for optimizing plant operations and

ensuring a reliable coal supply.

Stacker-Reclaimer at Grasim

Three Primary Motions of a Stacker-Reclaimer

A stacker-reclaimer is a versatile machine capable of both building and reclaiming coal

stockpiles. At Grasim, it performs these functions with three primary motions:

1. Longitudinal Travel: This motion allows the stacker-reclaimer to move along the
length of the stockpile. It's essential for covering the entire stockpile area during
both stacking and reclaiming operations.

2. Boom Elevation: This motion controls the vertical movement of the machine's
boom. During stacking, the boom is raised to deposit coal at the desired height.
During reclaiming, it's lowered to reach different levels of the stockpile.

3. Boom Slewing: This motion involves the horizontal rotation of the boom. It
enables the machine to cover a wide area while stacking or reclaiming coal.

These three coordinated motions allow the stacker-reclaimer to efficiently build and
extract coal from the stockpile, ensuring optimal utilization of the storage space.
Stacker-Reclaimer: A Closer Look

Key Components and Mechanisms

A stacker-reclaimer is a complex piece of machinery comprising several key

components:

● Chassis: The main frame that supports the entire structure.

● Travel Gear: Includes tracks or wheels for longitudinal movement.
● Boom: The long, articulated arm equipped with the stacking/reclaiming
mechanism.
● Hopper: A container at the end of the boom for holding the reclaimed coal.
● Conveyor Belt: Transports coal from the hopper to the main conveyor system.
● Hydraulic System: Powers the various movements and functions of the
machine.
● Electrical System: Controls the machine's operations and provides power to
various components.

Detailed Mechanisms

● Longitudinal Travel: Typically driven by electric motors and gearboxes, the

travel gear enables the stacker-reclaimer to move along the stockpile.
● Boom Elevation: A combination of hydraulic cylinders and linkages is used to
raise and lower the boom.
● Boom Slewing: A rotating mechanism, often powered by a hydraulic motor,
allows the boom to swing horizontally.
● Hopper: The hopper's position and orientation are controlled by hydraulic
cylinders to optimize coal loading and unloading.
 ● Conveyor Belt: Powered by electric motors, the conveyor belt transports coal
from the hopper to the main conveyor system.

Additional Considerations

● Stability: The stacker-reclaimer must be equipped with counterweights or

outriggers to ensure stability during operation.
● Safety Features: Emergency stops, alarms, and safety interlocks are essential
for operator safety.
● Maintenance: Regular inspections and maintenance are crucial for optimal
performance and preventing breakdowns.

By understanding the components and mechanisms of a stacker-reclaimer, operators

can maximize its efficiency and productivity while minimizing downtime

Coal Distribution and Feeding to Boilers

After the coal has been prepared and stored, it needs to be efficiently distributed to the
various boilers within the power plant.

Coal Feeders

Coal feeders are employed to regulate the coal flow into the boilers. These devices
ensure a consistent supply of coal to the burners.

● Types of Coal Feeders:

○ Rotary feeders
○ Vibrating feeders
○ Belt feeders
○ Screw feeders
○ Lock hoppers

The choice of feeder depends on factors such as coal characteristics, boiler capacity,
and desired feeding rate.

Coal Distribution System

The coal distribution system involves a network of conveyors and chutes that deliver
coal from the stockpiles to the individual boilers. This system often includes:

● Transfer points: To change the direction of coal flow.

● Weigh feeders: To accurately measure the amount of coal supplied to each
boiler.
 ● Coal bunkers: Intermediate storage hoppers near the boilers.

Challenges and Considerations

● Coal Flow Consistency: Maintaining a steady coal flow to the boilers is crucial
for optimal combustion.
● Coal Arching and Bridging: Preventing the formation of coal arches or bridges
in the bunkers.
● Coal Segregation: Ensuring that the coal blend remains consistent during
transportation.
● Dust Control: Minimizing coal dust generation and emissions.

By effectively distributing coal to the boilers, the power plant can achieve high
combustion efficiency and reduce fuel wastage

Bunker Placement: Why So High?

The strategic placement of bunkers at a significant height is a deliberate design choice

that serves several important functions:

Reasons for Elevated Bunkers:

1. Gravity Feed: By positioning bunkers at a higher elevation, the coal can be fed
to the feeders and subsequently to the boilers primarily through gravity. This
reduces the reliance on mechanical devices like feeders for coal movement,
thereby increasing system reliability and reducing energy consumption.
2. Coal Flow Consistency: A higher bunker facilitates a more consistent flow of
coal to the feeders. This is crucial for maintaining stable combustion conditions
within the boiler.
3. Arch and Bridging Prevention: The steep angle created by the elevated bunker
helps to minimize the formation of coal arches or bridges, which can obstruct
coal flow and disrupt the feeding process.
4. Space Optimization: While it might seem counterintuitive, placing bunkers at a
height can often optimize the overall layout of the coal handling plant, allowing for
efficient use of ground space.

By carefully considering these factors, engineers determine the optimal height for
bunkers in a coal handling system like the one at Grasim MHCP.
Major Challenges in Coal Handling and Innovative Solutions

Challenges

1. Coal Quality Variations: Fluctuations in coal quality, including ash content,

moisture, and calorific value, can significantly impact boiler performance and
emissions.
2. Equipment Failures: Breakdowns in critical equipment like conveyors, crushers,
and feeders can disrupt operations and lead to production losses.
3. Dust Generation and Environmental Concerns: Coal handling processes
often generate dust, leading to environmental issues and health hazards.
4. Energy Consumption: The coal handling process itself consumes significant
energy, impacting overall plant efficiency.
5. Coal Stockpile Management: Maintaining optimal stockpile levels while
preventing spontaneous combustion and material degradation is challenging.
6. Data Management and Optimization: Collecting and analyzing data to optimize
coal handling processes is complex and time-consuming.

Innovative Solutions

1. Coal Quality Optimization:

○ Real-time coal quality sensors to monitor incoming coal characteristics.

○ Advanced blending systems to create consistent coal blends.
○ Coal washing technologies to improve coal quality.
2. Equipment Reliability:

○ Predictive maintenance using IoT sensors and data analytics.

○ Redundant equipment and backup systems.
○ Modular equipment design for easier maintenance and replacement.
3. Dust Suppression and Environmental Protection:

○ Water sprays and misting systems to control dust generation.

○ Enclosed conveyor systems and transfer points.
○ High-efficiency dust collectors and filtration systems.
4. Energy Efficiency:

○ Variable speed drives for conveyors and other equipment.

○ Energy recovery systems to utilize waste heat.
○ Optimization of conveyor belt tension and alignment.
 5. Stockpile Management:

○ Automated stockpile management systems using drones and sensors.

○ Early warning systems for spontaneous combustion.
○ Covered stockpiles to reduce moisture and oxidation.
6. Data Analytics and Optimization:

○ Digital twin technology to simulate and optimize coal handling processes.

○ Advanced process control systems for real-time adjustments.
○ Artificial intelligence and machine learning for predictive analytics.

By addressing these challenges with innovative solutions, coal-handling plants can

improve efficiency, reduce costs, and minimize environmental impact.