# Design Considerations for a 1200 MW Coal Handling Plant
A coal handling plant (CHP) for a 1200 MW thermal power station requires meticulous planning to ensure efficient coal transportation, storage, and processing. The design must account for coal receipt, crushing, conveying, storage, and feeding to boilers while maintaining safety and environmental compliance. Below are key aspects of designing such a facility.
## Coal Receipt and Unloading System
The CHP must handle large quantities of coal delivered via rail, road, or ship. For a 1200 MW plant consuming approximately 15,000–20,000 tons of coal per day, mechanized unloading systems like wagon tipplers or rotary dumpers are essential. Rail-mounted hoppers with conveyor belts facilitate quick transfer to storage yards or crusher houses. Ship unloading may require grab cranes or continuous unloaders depending on port infrastructure.
## Crushing and Screening
Coal received from mines varies in size and quality. Primary crushers reduce large lumps (up to 600 mm) to manageable sizes (~200 mm), while secondary crushers further break them down (~25 mm). Vibrating screens segregate oversized particles for recirculation. Ring granulators or impact crushers are commonly used due to their high efficiency in handling Indian coal with high moisture content.
## Conveyor Belt System
Belt conveyors form the backbone of CHP operations. For a 1200 MW plant, multiple conveyors with capacities exceeding 2000 TPH are necessary. Steel cord reinforced belts ensure durability under heavy loads. Dust suppression systems along transfer points minimize fugitive emissions. Automated weighbridges monitor coal flow rates for optimal boiler feeding.
## Coal Storage and Stacking/Reclaiming
Coal is stored in open stockyards or covered sheds depending on environmental regulations. Stacker-reclaimers efficiently manage stockpiles by layering coal for blending different grades. Radial stackers offer flexibility in yard utilization while bucket wheel reclaimers ensure steady supply to downstream processes. Dust control measures like water sprinklers or wind barriers prevent air pollution.
## Coal Feeding to Boilers
From storage yards, coal is transported via conveyors to bunkers above boilers. Gravimetric feeders regulate flow rates based on boiler demand to maintain combustion efficiency. Surge hoppers buffer fluctuations between CHP output and boiler consumption rates during peak loads or breakdowns elsewhere in the system.
## Safety & Environmental Compliance
Fire detection systems (infrared scanners) prevent spontaneous combustion risks inherent in stored