flow chart of coal crusher
Flow Chart of Coal Crusher Operation
A coal crusher is a critical component in coal handling plants (CHPs) and thermal power stations. It reduces the size of coal to facilitate efficient combustion or transportation. Below is a detailed flow chart outlining the operational steps of a coal crusher, ensuring optimal performance and safety.
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1. Coal Feeding
The process begins with the feeding of raw coal into the crusher. Coal is typically transported via conveyor belts from storage yards or directly from mines. The feed size can vary, but it generally ranges from 500 mm to 1000 mm. Proper feeding ensures uniform distribution and prevents overloading.
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2. Primary Crushing
The raw coal enters the primary crusher, where large chunks are broken down into smaller pieces (approximately 100–200 mm). Common primary crushers include:
- Jaw Crushers: Use compressive force to break coal.
- Gyratory Crushers: Employ a conical head to crush coal against a stationary surface.
- Impact Crushers: Utilize hammers or blow bars to shatter coal.
Primary crushing reduces the load on secondary crushers and improves efficiency.
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3. Secondary Crushing
After primary crushing, smaller coal pieces move to secondary crushers for further size reduction (down to 20–50 mm). Common secondary crushers include:
- Roll Crushers: Use rotating cylinders to crush coal between them.
- Cone Crushers: Operate similarly to gyratory crushers but with finer output.
- Hammer Mills: Employ high-speed rotors with hammers to pulverize coal.
Secondary crushing ensures uniformity, which is crucial for combustion efficiency.
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4. Screening
Crushed coal passes through vibrating screens to separate oversized particles. These particles are recycled back into the crusher for reprocessing, while correctly sized coal proceeds downstream.
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5. Dust Suppression
Coal crushing generates dust, which poses health and safety risks. Dust suppression systems (e.g., water sprays or bag filters) are employed to minimize airborne particles and maintain air quality.
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6. Conveying to Storage or Boiler
The final crushed coal is conveyed to storage silos or directly fed into boilers for combustion. Proper sizing ensures complete burning and reduces emissions.
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Key Considerations
- Maintenance: Regular inspection of wear parts (e.g., liners, hammers) prevents breakdowns.
- Safety: Dust control and fire prevention