Theoretical session on stacker anr Reclaimer

1.Stacker
Introduction the interrmidiat storage of raw material between the query and the
raw mill has traditionally formed the stock pile from which a steady supply of
material for processing in the current work has been maintained.

Stacker the material stockpile are used both for staring and also for pre-
homogenation of the materil to be stocked. The material stockpiles of one pile can
be Reclaimed while the other stock pile is stocked

Process- the crushed limestone from the crushing unit is transported to stacker
section by means of belt conveyor (222bc5) and reach to boom of stacker ,boom
belt(222bc6) will drop the material on the ground on its side and make a pile . this
pile lenthe is 105 mts and width is 35 mts, stacker has a controlled rail drum (crd)
which supply the power to stacker . it has a loop car connect with a boggie by a
pain . loop car has a taper portion , material falls on this taper portion which comes
from ( 222 bc5) ,ant finally it falls on ground like straight line by the help of boom
belt and makes pile . the work of stacker is to make pile

Luffing Stackers

The luffing stacker travels along the entire length of the longitudinal stockpile conveyor and serves to
build a stockpile on one side of the conveyor only. The tripper is connected to the traveling stacker by
way of connecting structure and serves to transfer material to the boom. The stacker consists of a rigid
structural design with a boom pivot in the center. The luffing motion is often carried out by concrete
counterweight design. The stacker and tripper are designed for variable speed travel and can be quickly
relocated from one area of the stockpile to another. The luffing stacker can be operated in a manual,
semi-automatic, or fully automatic mode from a central control station. The luffing stacker is the most
cost-effective design for a stockpile on one side of the conveyor. With its simple structure, it has fewer
mechanical components than the slewing and luffing stacker.

Slewing Stackers

A traveling slewing stacker serves stockpiles to the left and right of the stockpile yard conveyor.
Controlled remotely, it can build a stockpile in chevron, coneshell, or windrow stockpiling modes.

Wing Stackers

one wing stacker fulfills the function of two luffing stackers and can be used to either stack two stockpiles
simultaneously or just one at a time. The material flow comes over a tripper car and is diverted to one or two
luffing booms. The structure in the center of the machine houses luffing winches for the luffing motion of the
booms and a flop gate to divert the material flow.
Radial Stackers

Radial stackers stockpile materials in a kidney-shaped pile, slewing between 90 and

approximately 360. Boom angles can be made either fixed or in a luffing motion between +15
to -15.

Side Boom Stacker/Reclaimer

The side boom stacker/reclaimer has the same reclaiming functions as the side boom reclaimer,
but a tripper trailer adds a stacking function. It transports material to the center of the transfer
table and discharges it into the scraper blades, which work in reversed rotation to build a
stockpile in a slow-motion traveling mode. To achieve a clean material transfer, a rotating flop
gate covers the reclaim opening. The side boom stacker/reclaimer can also send the incoming
material in bypass mode back onto the yard conveyor and reclaim additional material on top of
it, or can be used to stack and reclaim separately.

Tripper Cars

The tripper car serves to transfer the material flow from one part of the machinery to the next -
for example, from the stockyard longitudinal belt conveyor onto the conveyor in the boom of a
stacker.

2.Reclaimers
Reclaiming of the blending bet stock pile is carried by means of movable reclaimer
.the material is reclaimed from the stockpile by the forward movement of the
scrapped , travelled gears connect with the reversible car on the scraper bridge . the
rakes are mounted to the rake car and the material discharge by the scraper chain
drive

By this method reclaimer , it can also be employed in the caused of in homogeneous

material without any disadvantages type in material processing.
Process Reclaimer is also supplied by CIMMCO its capacity is 350 thp and 136
buckets . this reclaimer is moving steady and slowely in the direction of pile by the
help of buckets . Reclaimer reclaimes the lime stone from stockpile to raw mill
hopper through belt (222bc 2).Reclaimer has a harrow ,washe functioning is loose ,
the material from the stock pile , this harrow is fixed on rake car with the help of
harrow teeth material coming down with loose position . harrow is having speed is
10 mtr /min

Bucket-Wheel Stacker/Reclaimer

Bucket-wheel Stacker/Reclaimers travel on a rail track alongside the piles of material, offering
the potential to selectively stack and reclaim materials in different stockpile sections. This is
carried out in two quadrants (directions) on both sides of the track. Four-quadrant reclaiming is
possible with units featuring tripper-trailers that can be uncoupled. Active stockpiles may be
stacked and reclaimed within the traveling limits and operating radius - up to the boundary zone
of the storage area on the boom side of the machine. On the trailer side, a clear space, or box cut,
is provided, which permits the bucket-wheel to cut into a free end face of the pile.

Bucket-Wheel Reclaimer
Bucket-wheel reclaimers, traveling on a rail track alongside the piles of material, can reclaim
stockpile sections selectively. This is carried out in four quadrants (directions) on both sides of
the track. Within the traveling limits and operation radius, active stockpiles can be deposited and
reclaimed up to both boundary zones, and the bucket-wheel can cut into them from both ends.

Bridge Type Scraper Reclaimer

The bridge reclaimer, in conjunction with the proper stacking method, offers the very high
blending ratio often required for homogenizing limestone, coal, iron ore, and other materials.

The bridge type box girder spans the pile and supports a trolley that reciprocates its travels
gradually along the length of the box girder. Suspended from the trolley are triangular harrows
(or "rakes"), one per side, loosening the material on the pile cross-section. Each harrow is
adjusted to a slanted position, matching the angle of repose of the stacked material. As the bridge
reclaimer inches towards the pile, the harrow loosens the material so that it runs under gravity to
the foot of the pile. There, a scraper chain collects the material and transports it to the yard
conveyor. The reclaimed capacity is controlled by varying the travel speed of the machine.

Bridge Type Bucket-Wheel Reclaimer

The bridge type bucket-wheel reclaimer blends and homogenizes material that has been piled up
to the chevron system stackers of a blending yard. The bucket-wheel trolley on the main girder
travels on eight vertical rollers. Four horizontal rollers at the level of the lower bridge chord
ensure lateral guidance of the trolley. The trolley travel speed is adjustable so that, in connection
with the variable cutting depth, optimum operating conditions can be chosen for reclaiming a
variety of materials.

The trolley features two bucket wheels, each equipped with two rakes, and moves parallel to the
front end to take up the material that has been stripped off by the rakes. Each cross-travel of the
trolley is followed by a forward step of the complete machine. As the two buckets are
transposable, the machines can operate in two directions-an essential advantage for stacking one
stockpile while reclaiming another. Each of the bucket-wheels is driven by a short-circuit rotor
motor through a hydraulic safety clutch, a worm gear, and a succeeding auxiliary spur wheel
gear.

Bridge type bucket-wheel reclaimers can be designed for manual as well as automatic operation.

Bridge Type Drum Reclaimer

Bridge type drum reclaimers are high capacity reclaimers for blending materials such as coal,
limestone, ore, etc. Working in one or two reclaim directions, these reclaimers span stockpiles up
to 140 feet wide and feature capacities of 5000 stph in coal.
Trencher Reclaimer

The trencher bucket-wheel reclaimer differs from other reclaimer types in its mode of operation,
recovering material by travel movement rather than slew movement. The material is reclaimed
with the bottom part of the bucket-wheel cutting periphery.

Due to the narrow stockpile width, the boom can be short but the wheel diameter must be in
relation to the active stockpile width.

Trencher type units can also be supplied as dual-purpose (stacker/reclaimer) machines.

Circular Stacker/Reclaimers
The circular stacker/reclaimer is designed for 360 degrees of rotation. The design consists of a
slewing and luffing stacker to stack the material, a bent chain slewing and luffing reclaimer and a
central column which includes a feeding and discharge hopper. The stacking and reclaiming
systems operate independently.

Side Boom Reclaimer

The side boom reclaimer travels alongside a stockpile on two rails with a rail gauge measuring 3
to 5 meters and supported by travel bogies with a three-point system. The luffable reclaim boom
ranges in length from 10 meters and 30 meters and normally reclaims low tonnages of 50 tph, but
it can also reclaim tonnages as high as 1000 tph. It has a luffing winch, a scraper reclaim drive
and a travel drive. This lightweight reclaimer is one of the most economical for low tonnages.
Technical data for stacker
Stackin Rate; 600tph

Boom length ; 19.5

Trake guage ; 4 mtr

No of wheel; 4

No drive wheel; 2

Wheel dia; 630 mm

Effective roll dia; 80 mm

Belt c/c distance for boom; 21.5

Belt quality; 315/3 nylon or esp

Belt cover thickness; 585 mm

TOP BOTTM

BELT SPEED;17.5 M/SEC MAX

BELT THROUGH ; 30 DEG

Travel speed;30 KW
BELT DRIVE; 2*75 KW

LOOP CAR

Make : Electro zardo

Type : EZ 764/2

Dimension : dia 3400mm

Width : 52 mm

Troque rating : 4.5 n-m

Nominal voltage : 415 apron

Conveying data : 600 tph

Belt width : 1000 mm

STACKER BOOM

Squirrel cage motor make : bharat bijlee

Type : sc casper motor

Power : 36 kw

Nominal speed : 1500 rpm

Voltage : 415/50

Double slow break : 5

Make : techno cars

Type : electro hydraulic

Break drum dia : 300 mm

Technical data for Reclaimer

Reclaimer rate : 350 tph

Rail span : 31.5mm

No of drive wheel : 2

Wheel dia :630 mm

Effective roll head width required: 80mm

c/c distance of scrapper chain: 33mm

Scrapper blade width : 1100mm

Speed of chain scrapper conveyor : 0.45 m/sec max

Rake travel : 14.5 mm

Cahain drive : 55 kw
Travel drive reclaimer : 2*0.1 kw

Fast : 2*5.5 kw

RaCK drive : 1*15 kw

RACK CAR

SQUIRREL CAZE PORT MAKE : BHARAT BIJLEE

TYPE: SC 15 KW

NOMINAL SPEED :1500V/HZ

TYPE : ELECTRO HYDRULIC

BREAK CLINK DIA: 200*85MM

Scrapper chain

Single cagemotor

Make : Siemens

Type : squirrels

Nomial speed: 1800 rpm

Nominal voltage: 415/50

WEIGH FEEDER
Oil quantity : 5 ltr

Frequency of oil change: 2 year

Gera box make : Redicon

Size: A337

Ratio : 60:1

Reducer make : Gyrox

Ratio: 4:1
Belt length : 1000mm

Fed hopper in RCC construction

Storage capacity: 500 tph 100 ton

Material stored: low grade lime stone high grade lime stone and latrite

Feed hopper in steel contruction storage capacity : 100

Scapper chain material storage : bauxite & gypsum

Belt conveyors
Belt
C/C Total
Sr.No Belt Widt Cap. Grade
Description Length Length
. No. h (TPH) Ply.
(Mtr.) (Mtr.)
(MM)
212BC
1 800 250 17.85 39
1 Below Grizzley to 212 BC 2 315/3
212BC From 212 BC 1 to vib.
2 800 250 19.87 44
2 Screen 315/3
212BC
3 800 250 75.00 165
3 From 212 BC 2 to 212 BC 4 315/3
212BC
4 800 250 75.00 165
4 212 BC 3 TO Reject 630/3
212BC
5 800 250 17.36 39
5 From 212 BC 3 To 222 BC 2 315/3
222BC
6 1200 700 17.01 37
1 Below lime stone crusher 630/4
222BC Inclined RBC at Tunnel
7 1000 700 39.99 88
2 L.S.C. 500/3
222BC Over land RBC l.STONE 1112.9
8 1000 700 2200
3 Crusher 7 1000/4
222BC PWD Crossing L.Stone
9 1000 700 156.77 330
4 crusher 500/3
222BC
10 1000 600 368.50 780
5 Stacker Belt 800/4
222BC
11 1000 600 21.50 48
6 Stacker Boom Belt 500/3
232BC
12 1000 600 35.65 76
1 By Pass Belt 500/3
232BC
13 800 350 506.00 1062
2 Reclaimer Belt 800/4
232BC
14 800 250 5.50 13
3 Gypsum Belt 315/3
232BC
15 600 100 42.350 90
4 HGLS Ground Hopper to CR 315/3
232BC Additive G/H to Crusher
16 800 100 57.527 121
5 (Taterite ) 315/3
232BC TP 232 BC 5 Crusher to 232
17 600 100 33.500 72
6 bc 4 (TP) 315/3
 232BC
18 600 100 28.50 60
7 TP 232 BC 4 to 232BC 7 315/3
232BC From 232 BC 7 to RM
19 600 100 75.0 158
8 Hopper 315/3
232BC HGLS /Laterite on hopper top
20 600 100 90 20
9 ( R) 315/3