STACKING

STACKING
 STACKING MANUAL

MISSION
TO TRANSFORM NATURAL RESOURCES INTO PROPERITY
AND SUISTAINABLE DEVELOPMENT

VISION
TO BE NUMBER ONE GLOBAL NATURAL RESOURCES
COMPANY IN CREATING LONG TERM VALUE,THROUNGH
EXCELLECE AND PASSION FOR PEOPLE AND THE
PLANET
STACKING MANUAL

VALUES

LIFE MATTERS MOST

VALUE OUR PLANET
PRIZE OUR PLANET
DO WHAT IS RIGHT
IMPROVE TOGETHER
MAKE IT HAPPEN
 STACKING MANUAL

OBJECTIVE

TO UNDERSTAND WHAT IS STACKING.

TO UNDERSTAND THE METHODS OF STACKING.
TO KNOW ALL THE RISKS DURING STACKING.
 YARD AREA
BUFFER MATERIAL
PILE A

ER-02
TR-09

IOCJ
PILE B

EP-03
TR-08

SFHT
PILE C

RC-05
TR-07

BLENDED PRODUCT
PILE D

ER-04 ER-01
TR-04
TR-06

BLENDED PRODUCT
PILE E
STACKING MANUAL

STOCKPILE
STACKING MANUAL

STACKING OPERATION
 STACKING MANUAL

WHAT IS STACKING?
STACKING IS ONE OF THE PRODUCTIVE PROCESS OF PORT OPERATIONS
DESIGNED TO IMBUE SUBSEQUENT PROCESSES WITH QUALITY AND
PERFORMANCE;
IT IS A PROCESS IN WHICH A STACKER OR STACKER/RECLAIMER IS USED TO
STOCKPILE PRODUCTS THAT FOR THE MOST PART IMPORT AND BLENDING
PROCESS.
THE TYPE OF STACKING TO BE UNDERTAKEN WILL BE INFORMED BY THE CONTROL
ROOM
THE STOCKPILES MUST HAVE AN ADEQUATE GEOMETRIC SHAPE FOR IMPROVED
PERFORMANCE IN RECLAIMING OPERATIONS
 STACKING MANUAL

VIDEO
 STACKING MANUAL

VIDEO
STACKING MANUAL

STACKER AND
STACKER/RECLAIMER
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STACKER
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STACKER

MAST
BOOM COUNTERWEIG
HT
CABIN
FIXED TRIPPER

SLEW

ELECTRICAL
GANTRY ROOM
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STACKER/RECLAIMER
 STACKING MANUAL

STACKER/RECLAIMER

COUNTER
WEIGHT

TRIPPER
BOOM MAST
BUCKET TRAILER
WHEEL

SLEW

GANTRY ELECTRICAL
ROOM
 STACKING MANUAL

TRIPPER
THE PART THAT UP OR DOWN DEPEND TO THE PROCESS.
WHEN UP, IT IS IN POSITION FOR STACKING;
IT FEEDS THE TRAILER CONVEYOR;

TRAILER
TRIPPER
 STACKING MANUAL

MANUAL MODE

THE STACKER OPERATE FROM INSIDE THE CABIN BY OPERATOR.

WILL USE THE JOYSTICKS TO CONTROL LUFFING, SLEWING AND TRAVELING.

STOCKPILING OF THE MATERIAL WILL BE ENTIRELY CONTROLLED BY THE OPERATOR, WITH

FORMATION OF THE STOCKPILE COMPLETED AS PLANNED, INCLUDING MAXIMUM HEIGHT AND
WIDTH.
 STACKING MANUAL

CABIN

HMI CAMERA JOYSTICK

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VIDEO
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AUTOMATIC MODE

OPERATION CONTROLLED BY MONITORING AND CONTROL SOFTWARE. IN THIS OPERATION

MODE, THE SYSTEM IS RESPONSIBLE FOR MOTION CONTROL

OPERATING AND MONITORING STATION AT THE CONTROL ROOM

COMPOSED OF A COMPUTER, VIDEO MONITOR,CCTV MONITOR AND IMAGE CAPTURE SYSTEM.

 STACKING MANUAL

STACKING METHODS

* Chevron

* Windrow

* Cone

* Multicone

* Coneshell
 STACKING MANUAL

WINDROW
• CONCEPT

*CONSISTS OF STOCKPILING IN SEVERAL PARALLEL CONES.

 STACKING MANUAL

WINDROW
 STACKING MANUAL

WINDROW
• BENEFITS:
*REDUCTION OF GALNUMETRIC SEGREGATION;
(COARSER AND SMALLER PARTICLES ARE SPREAD OUT
THROUGHOUT THE STOCKPILE);
*BETTER HOMOGENIZATION OF THE COMPONENTS OF THE
STOCKPILE;
*MORE EFFICIENT USE OF THE STOCKPILING AREA.

• DISADVANTAGES:
*MAKES IDENTIFICATION AND DECONTAMINATION OF IMPURITIES
DURING STOCKPILING DIFFICULT;
*THE ADDITION OF CORRECTIVE ORES DURING STOCKPILE
FORMATION MAY CAUSE A GREAT VARIATION IN QUALITY.
 STACKING MANUAL

HOMOGENIZATION OF A WINDROW
STOCKPILE
 STACKING MANUAL

STOCKPILE FORMATION
THE FIRST LINE IS FORMED WITH THE BOOM AT 90 DEGREES;
THIS LINE HAS THE PURPOSE OF AIDING IN SUSTAINING THE STOCKPILE;
EACH LINE CAN BE FORMED WITH ONE OR MORE PASSES OVER IT;

EP
 STACKING MANUAL

STOCKPILE FORMATION
AFTER THE FIRST LINE, ANOTHER PARALLEL LINE WILL BE FORMED,
AND SO ON, SUCCESSIVELY;

EP
 STACKING MANUAL

STOCKPILE FORMATION
AFTER THE FIRST LINE, ANOTHER PARALLEL LINE WILL BE FORMED,
AND SO ON, SUCCESSIVELY;

EP
 STACKING MANUAL

STOCKPILE FORMATION
AFTER THE FIRST LINE, ANOTHER PARALLEL LINE WILL BE FORMED,
AND SO ON, SUCCESSIVELY;

EP
 STACKING MANUAL

STOCKPILE FORMATION
AFTER THE FIRST LINE, ANOTHER PARALLEL LINE WILL BE FORMED,
AND SO ON, SUCCESSIVELY;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE LAST LATERAL LINE WILL ALSO BE A LINE AIDING IN SUPPORTING
THE STOCKPILE DURING ITS FORMATION;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FIRST LINES OF THE NEXT ORE WILL BE FORMED BETWEEN THE
LINES OF THE PREVIOUS ORE.

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FIRST LINES OF THE NEXT ORE WILL BE FORMED BETWEEN THE
LINES OF THE PREVIOUS ORE.

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FIRST LINES OF THE NEXT ORE WILL BE FORMED BETWEEN THE
LINES OF THE PREVIOUS ORE.

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FIRST LINES OF THE NEXT ORE WILL BE FORMED BETWEEN THE
LINES OF THE PREVIOUS ORE.

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FIRST LINES OF THE NEXT ORE WILL BE FORMED BETWEEN THE
LINES OF THE PREVIOUS ORE.

EP
 STACKING MANUAL

STOCKPILE FORMATION
AS THE LAST LINE CANNOT BE FORMED BETWEEN THE LINES OF THE
PREVIOUS ORE, THIS LINE WILL BE FORMED ON THE ORE THAT IS BEING
STOCKPILED;
THIS LINE WILL BE FORMED A LITTLE FURTHER FROM THE LINES AT THE
EDGES OF THE PILE TO AVOID RISKS OF POTENTIAL COLLAPES;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FIRST LINES OF THE NEXT ORE WILL BE FORMED ON THE LINES OF
THE PREVIOUS ORE, PREFERENTIALLY AT THE OPPOSITE END OF THE
STACKER;
THESE LINES WILL ALSO BE PARALLEL TO EACH OTHER;

EP
 STACKING MANUAL

STOCKPILE FORMATION
AFTER THE FIRST LINE, ANOTHER PARALLEL LINE WILL BE FORMED,
AND SO ON, SUCCESSIVELY;

EP
 STACKING MANUAL

STOCKPILE FORMATION
AFTER THE FIRST LINE, ANOTHER PARALLEL LINE WILL BE FORMED,
AND SO ON, SUCCESSIVELY;

EP
 STACKING MANUAL

STOCKPILE FORMATION
AFTER THE LINE FORMED BESIDE THE PREVIOUS ORE, ANOTHER LINE
WILL BE FORMED ON THE OTHER SIDE OF IT;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE LAST LINES WILL BE FORMED BETWEEN THE LINES OF THE SAME
ORE;
THESE LINES WILL BE FORMED A LITTLE FURTHER FROM THE END OF
THE STOCKPILE TO AVOID POTENTIAL RISKS OF COLLAPSE;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE LAST LINES WILL BE FORMED BETWEEN THE LINES OF THE SAME
ORE;
THESE LINES WILL BE FORMED A LITTLE FURTHER FROM THE END OF
THE STOCKPILE TO AVOID POTENTIAL RISKS OF COLLAPSE;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FIRST LINE OF THE NEXT ORE WILL BE FORMED BETWEEN THE
LINES OF THE PREVIOUS ORE, PREFERABLY AT THE OPPOSITE END OF
THE STACKER;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STACKING MANUAL

STOCKPILE FORMATION
THE FORMATION OF THE STOCKPILE WILL BE EXECUTED IN SEQUENTIAL
LINES, FIRST FILLING IN THE SPACES LEFT BETWEEN THEM, THEN ON
TOP OF THEM;

EP
 STOCKPILING MANUAL

STOCKPILE FORMATION
THE TIME HAS COME FOR US TO FINISH THE STOCKPILE, FILLING SPACES AND
COMPACTING SALIENTS LEFT OVER FROM THE FORMATION PROCESS;

EP (Stacker)
 STOCKPILING MANUAL

STOCKPILE FORMATION
WE WILL GO OVER THE STOCKPILE, ALLOWING THE ORE TO SPILL OVER BOTH SIDES;

Stacker
 STOCKPILING MANUAL

STOCKPILE FORMATION
WE WILL FINISH THE STOCKPILE, LEAVING IT IN THE SHAPE OF A PRISM;

Stacker
 STACKING MANUAL

CHEVRON
• CONCEPT
This method is when the stacker travels along the length of
the stockpile adding layer upon layer of material.
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CHEVRON
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SINGLE CONE
• CONCEPT

*CONSISTS OF STOCKPILING MATERIAL INTO A SINGLE CONE.

 STACKING MANUAL

SINGLE CONE
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MULTI-CONES
• CONCEPT
*CONSISTS OF STACKING SMALL CONES (APPROXIMATELY 2
METERS HIGH), DISTRIBUTED THROUGHOUT THE STOCKPILE.
 STACKING MANUAL

MULTI-CONES
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CONESHELL/CONEVRON
• CONCEPT

*CONSISTS OF STACKING COMPLETE CONES AT SMALL

DISPLACEMENTS, MAKING UP A SINGLE PILE.
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CONESHELL/CONEVRON
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QUALITY
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VARIABILITY
DEFINITION: THIS IS THE DIFFERENCE IN QUALITY BETWEEN THE
DIFFERENT ORES THAT MAKE UP THE STOCKPILE;

NATURAL VARIBAILITY EXISTS, DUE TO: DIFFERENCES IN THE QUALITY

OF THE COMPONENTS, WHICH MAY ORIGINATE FROM DIFFERENT
MINES;

SEGREATION WITHIN A SINGLE PRODUCT.

TO ACHIEVE A LOWER RATE OF VARIABILITY IN THE PRODUCT TO BE

SHIPPED, EFFICIENT STOCKPILING, RECLAIMING, LOADING AND
SAMPLING METHODS ARE REQUIRED.
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SEGREGATION

DEFINITION: THIS THE CONCENTRATION OF PARTICLES OF A PRODUCT

IN DIFFERENT PARTS OF THIS SAME PRODUCT, DURING HANDLING;

THIS HAPPENS LARGELY DUE TO DIFFERENCES IN SIZE, FORM AND

DENSITY OF THE PRODUCTS.
 STACKING MANUAL

SPACING BETWEEN STOCKPILES

STOCKPILES SHOULD BE FORMED WITH SPACES OF ABOUT 10 METERS
BETWEEN THEM. THIS SPACE ENABLES THE BUCKET WHEEL TO TURN WITHOUT
RECLAIMING PART OF THE STOCKPILE THAT IS BESIDE IT, OR WITHOUT
COLLIDING WITH IT.
 STACKING MANUAL

RISKS WITH NIGHT OPERATIONS

POINTS TO BE CONSIDERED FOR PROPER NIGHT OPERATIONS:
REST PROPERLY PRIOR TO WORKING AT NIGHT;
ALL LIGHTING SHOULD BE FUNCTIONING PROPERLY;
AVOID LOOKING DIRECTLY INTO THE LIGHTING;
 STACKING MANUAL

COLLAPSE OF STOCKPILES

SOME FACTORS CAN CAUSE THE COLLAPSE OF STOCKPILE:

1 – Over-wet material.
2 – Site with poor drainage;
3 – Pile formation causing collapse ;
4.1 – Narrow base in proportion to pile height, providing less support;
4.2 – Not following of Standart Operation procedure(SOP).
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VIDEO
STACKING MANUAL
STACKING MANUAL

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