At our coal wagon tipplers, some quantity of remnant material is left inside the wagons post tippling. The remnant coal inside the wagons has to be cleaned manually, which involves a lot of manpower. To do the cleaning activity, cleaning people have to move inside and out of the tippled empty wagons at the outhaul area of tippler while empty wagons are getting pushed. This activity of manual cleaning of unloaded wagons has to be done while the unloading process is going on at tippler and is a very hazardous activity. Around 30 to 50 T of spillage coal is generated on an average per day due to remnant coal in wagons which doubles during monsoon. The remnant coal of different rakes is accumulated after cleaning which gets converted into mix spillage coal and is a loss of prime domestic and imported coals.
The challenge is to eliminate remnant coal in wagons post tippling and thereby eliminate wagon cleaning activity and generation of spillage coal.
Options tried to solve before:
1. Mechanical modification was done at clamping area to prevent back falling of coal material inside wagons after tippling.
2. Air pressure of 10 bar used to prevent accumulation of coal at clamp area.
The solution MUST fulfill the following requirements:
1. Zero remnant coal inside wagons post tippling and eliminate the hazardous activity of manual cleaning.
2. Eliminate generation of mix spillage coal at tippler area post tippling to prevent loss of prime imported and domestic coal.
3. The complete material from wagons should get unloaded after the tippling activity.
4. Some mechanized solution of cleaning remnant coal from wagons can be introduced in place of manual cleaning.