Coal handling plants are the backbone of every thermal power plant. Efficiently handling of coal ensures that the plant remains productive and efficient. If coal is not handled properly, the plant can suffer from problems like boiler efficiency loss, ash handling issues, and environmental concerns. Therefore, an essential part of any coal handling system is the crusher.

A crusher is a machine used to reduce the size of coal to a manageable size for transportation and processing purposes. In simple terms, a crusher can be thought of as a giant 'nutcracker' that is used to break down large pieces of coal into smaller chunks.

There are several types of crushers commonly used in coal handling plants, including jaw crushers, gyratory crushers, hammer crushers, and roller crushers.

Jaw Crushers:

Jaw crushers are used for coarse grinding brittle, medium-hard to hard materials up to a Mohs' hardness of approx. 8.5. They are mainly used in quarries, mining, recycling, and processing industries. Jaw crushers consist of one fixed and one movable crushing jaw. Due to their simple design and easy maintainability, jaw crushers are widely used as primary crushers in coal handling plants.

Gyratory Crushers:

Gyratory crushers are used for primary crushing of various materials in the mining, building materials, and stone industries. The main shaft and the crushing cone are supported on a circular disc fixed with vertical axles, which are mounted in the spider assembly. With the gyratory motion of the crushing cone in the cone cavity of the shell, the ore block is squeezed and broken.

Hammer Crushers:

Hammer crushers are used for the crushing of coals with a high moisture content, as well as lignite and pit coal. The crushing of the feed material is effected by percussion, impact, and shear forces. A reversible hammer crusher is typically used.

Roller Crushers:

Roller crushers are used mainly for crushing easily fractured materials such as soft limestone, chalk, and clay. They are also used for secondary crushing of middlesized materials. Roller crushers are reliable, rugged, and maintenance-friendly machines.

Each type of crusher comes with its own set of advantages and disadvantages depending on the specific application. Jaw crushers are well suited for softer materials, while gyratory crushers are ideal for hard and abrasive materials. Hammer crushers provide good reduction ratios and can handle a wide range of materials, while roller crushers are efficient for medium-hard to hard materials.

In addition to the different types of crushers, the coal handling system also includes a variety of auxiliary equipment such as vibrating feeders, vibrating screens, magnetic separators, conveyors, and various types of storage systems.

To wrap up, crushers play an important role in the coal handling system of a thermal power plant. The main purpose of a crusher is to reduce the size of coal so that it can be transported and processed efficiently. Knowing the different types of crushers available and understanding their strengths and weaknesses will help coal handling plant operators make informed decisions when choosing equipment for their specific needs.