Millmerran Power Station ROM coal blockage removal system

Abstract

[Abstract]: Millmerran Power Station (MPS) consists of two units with each unit producing 420 MW of electricity. The coal is delivered to the plant by off road type trucks and unloaded into a 500 MT hopper. The ROM (run of mine) coal is processed through a series of crushing stations and coal handling (storage/reclaim) systems, and delivered by overland conveyor to the power plant silos. MPS, as a coal fired station, is wholly dependent on a consistent and reliable supply of coal to maintain operating efficiency. MPS has been experiencing inefficiencies in their ROM coal supply because of constant blockage issues at the receiving hopper. This blockage is a direct result of large lumps of coal coming from the mine. The blockages interrupt the supply of coal potentially lowering the fuel supply to the power station. Currently, an excavator is hired to clear up the blockage which could be utilised more effectively elsewhere. This introduces an extra cost to the mine in terms of both money and inefficiency. MPS is seeking an engineering design solution to this problem. The elimination of the blockages through an automatic system without increasing any safety risks is highly desirable as that would result in a cheaper and smoother operation of the mine. A literature review on the current coal handling system of MPS was essential in order to be able to develop a design that is suitable for MPS. In this investigation, five conceptual designs with the most appropriate design, in terms of meeting the specified criteria, was analysed and detailed. It was found that the simpler and more effective the design, the higher its practicality in terms of reaching the desired objectives. This enabled an overall cost estimate budget to be produced, which would be the major deciding factor on the implementation of the design. The results of this investigation will aid in gaining an understanding of the overall general solution for the ROM coal blockage problem at MPS. Both design and engineering solutions have been recommended in this dissertation. This will lead eventually to a more automated, safer, efficient and cost effective operating environment.