Conveyors This is How to Convey Coal Skillfully

Adani Group’s Dahej port, one of the sophisticated ports in the country, needed an apt system to transport coal from the shore to the railway line. To resolve this issue, it built a state of the art conveyor system. This system is elevated and passes through busy roads, village and industrial area. Here is an overlook at the system and its design.

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When Adani Group at Dahej wanted a conveying system to transport coal from its port at Dahej to the private railway line, which is around 4.75 km away, PMC Projects, a subsidiary of the Adani Group, approached Conveyor Dynamics, Inc (CDI). Initially, CDI was awarded a contract to produce a basic engineering design of the elevated silo conveyors and a basic engineering design for the Adani Power Conveyor system that PMC intended to build in the future to transport coal from the terminus of the second silo conveyor to a new power plant they will build around 10.85 km away.

After CDI completed the basic engineering, PMC realized that acquiring the land in the conveyor corridor posed a significant challenge. To avoid large change orders, the Adani group decided to handle all procurement, construction and project management in-house.

Three Conveyors, 6000 Tons of Coal and One Solution

The silo conveyor system is comprised of three conveyors connected in series that transport up to 6,000 tph coal from the Dahej port to a rail wagon loading silo. The first conveyor in the series is SC-1A (Silo Conveyor 1A). It is 1.6 km long and gains 6.7 m of elevation. The conveyor transports up to 6,000 tph coal on an ST1000 1,600 mm wide belt traveling at the speed of 7.5 m/s.

Two horizontal curves with 1,100 m radii and nine vertical curves with various radii are included in the conveyor route. Most of the conveyor is located in an elevated gallery that is 6 m above the ground except where the conveyor crosses roads where the gallery elevation rises to 9m above the road grade. The SC-1A is powered by two 500 kW inverter driven motors, and includes two brakes. One brake is located on the tail pulley and the other is located within the take-up sheave assembly.

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This second brake is used to boost the takeup tension during an unpowered stop. The SC-1A discharges onto the second conveyor in the series tagged as SC-2A. This conveyor is 1.4 km long and gain 8.7 m of elevation. It transports up to 6,000 tph on an ST1000 1,600 mm wide belt traveling at 7.5 m/s. Like SC-1A the entire conveyor is elevated at 6 m off the ground and it is powered by two 500 kW inverter driven motors.

Currently, SC-2A directs feed onto a 485 m long low speed conveyor tagged as SC-3. However, SC-2A’s discharge chute includes a diverter gate that will allow SC-2A to discharge coal onto the Adani Power Conveyor system in the future. The SC-3 discharges coal into the rail wagon loading silo.

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