Innovative solution for high-capacity coal conveying system in power plants

FLSmidth Wadgassen designed and audited the system, which was designed to convey and stack coal at 6800 tph

FLSmidth Wadgassen designed and audited the system, which was designed to convey and stack coal at 6800 tph

Coastal Gujarat Private Limited—A Tata Power Company—became India’s first commissioned 4000 Mega Power Project (UMPP) to use super critical boiler technology.

The project has been successful despite the tight delivery schedule, site challenges, and the high demands from the client in regard to safety and quality. This project will serve as a reference point for future undertakings.
— R B Venugopal Marketing & Sales - India FLSmidth India

In June of 2009, FLSmidth was awarded the Coastal Gujarat contract—which included the engineering, supply, and construction of an “External Coal Handling System” (ECHS) for the power plant mentioned above to transport coal from the Adani West Port to the power plant, which is situated 12 kilometers away. The system  is comprised of a series of high capacity and high speed Belt Conveyors and a Bucket Wheel Stacker Reclaimer—one of the world’s largest in operation for the coal industry. It will also include the associated electrical and automation systems combined with utilities, structural and civil works.

As the technology center for this project, FLSmidth Wadgassen designed and audited the system, which was designed to convey and stack coal at 6800 tph. It will also reclaim and convey coal from the stockyard to the plant at 4500 tph.

Prof. Dr. ir. Gabriel Lodewijks (President, Converyor Experts B.V.) served as a consultant for the conveying system from the proposal stage to the finalisation of the design. He also performed the dynamic analysis of the conveyors and selected the energy-efficient belting and rollers, which operate with lower rolling resistance.

FLSmidth encountered several challenges in executing this order, including the directive to conceive an energy-efficient material handling system. Critical components such as belts, idlers, pulleys, drives and electrical equipment, which were sourced from around the globe, had to meet international quality standards. Lastly, the 12 km reclaiming distance was to include 35,000 m3 of concrete, approximately 4600 cast-in-situ bore piles—each 25 metres long—and 3200 tonnes of steel. This was to take place in a period of 18 months.

To meet these challenges, FLSmidth partnered with IVRCL Infrastructure & Projects Limited, a premier construction company in India. The two companies worked together seamlessly to deal with the adverse site conditions and within the tight schedule.

The ECHS was completed by the end of February, 2011, and the first vessel was unloaded on March 7, 2011. From that time until April, 2011, more than 300,000 tonnes of coal was unloaded in the stockyard at the rate of 5600 tph. Tests confirmed that the system was ready to operate continuously while unloading the vessels around the clock.

The site is now prepared to undergo performance guarantee tests for both capacity and specific power consumption.
Operating data from the entire coal handling system clearly indicates that the system consistently operates at a higher level than the guaranteed figures specified—despite the fact that the original figures were competitive in reference to FLSmidth’s global competitors.

We are confident that this type of performance will continue.

Due to the magnitude of the project in terms of civil and structural works and in terms of the conveying capacity and size of the Bucket Wheel Stacker Reclaimer, this has become FLSmidth India’s flagship project. The project has been successful despite the tight delivery schedule, site challenges, and the high demands from the client in regard to safety and quality. This project will serve as a reference point for future undertakings.

CONTACT: R B Venugopal