3.3.

3 Stacking and Reclaiming

One mission of a material handling system is to stack coal, iron ore, fertilizer, and other
bulk materials in piles, or to reclaim and move them from storage to another location. The
operation of building a pile is called “stacking,” and removing and relocating operations are
called “reclaiming.” Stackers and reclaimers are specialized for their respective operations, but a
stacker-reclaimer is capable of handling both (Kawasaki, 2018).

3.3.3.1 Stacker

Stackers are used to produce these large piles or circular stacks. The function of the
stacker is to pile bulk materials such as coal and iron ore onto a stockpile. Stackers normally
travel on rail between stockpiler in the stockyard (Van Vianen, 2010). It has three (3) basic
movements:

1. Luffing - stackers whose boom can be luffed to move along the rail. It is moving
vertically. Either a pulling mechanism with wires of metal or a pair of hydraulic
cylinders are used by stackers. When compared favorably to hydraulic actuators,
winch mechanisms are still frequently utilized, especially in large stackers.
2. Luffing and Stewing Stackers - Stackers that in addition to travelling and luffing of
the boom, also are able to slew or rotate the boom. This type of stacker is the most
versatile since it is able to slew from a stockpile to the other side of the yard conveyor
and build equal stockpiles on both sides of the yard feed conveyor on to the boom
conveyor (Foerdertechnik, 2010).
3. Radial Stackers Stackers that are positioned on a fixed place and stockpile material in
a circular storage system by slewing the boom up to 360°. A radial stacker is a
conveyor that sits on a wheeled truck which runs on a railed track that forms a radius
semi-circle around the stacker. The advantage of the radial stacker is that it gives the
operator the option to create many multiple stacks of material or one continuous
radial stack. The stacker pivots at one end with the other end able to be raised and
lowered (Wagner, 2019)
3.3.3.2 Reclaimer

The machine reclaims the material from the stockpile in layers by rotating bucket wheel
swing across the pile. The material picked up by the bucket is retained and guided by the ring
chute as the bucket moves up. When the bucket is about 45 deg above horizontal, the material
starts discharging it to the bucket wheel chute, which guides it to the boom conveyor (CHP,
2024). There are three (3) types of reclaimers:

1. Bucket Wheel Reclaimers - Reclaimers that remove material from the stockpile
using buckets. On a revolving wheel are the buckets mounted. A bridge or a boom can
support the bucket wheel. Whether designed as standalone reclaimers or as a hybrid
stacker/reclaimer, bucket wheel reclaimers are the most efficient way to handle and
move large volumes of bulk materials in the shortest amount of time. It is used for
handling huge volumes of coal, ores, and other materials in ports, power plants,
stockyards, or in steel plants. The scooped material falls on the receiving or
intermediate conveyor and the conveyor discharges the material on the yard conveyor
(Shah, 2019).
2. Scraper Reclaimers - Reclaimers that use a chain with gathering scrapers. These
scraper reclaimers are using the bridge, portal and side scraper constructions. In
scraper reclaimers, scraper blades are attached to two parallel strands of chain at
regular interval. The travel of chains along with the scraper blades, scrapes or drags
the material from the stockpile and it discharges it on the yard conveyor (Shah, 2019).
3. Drum-Type Reclaimers - Reclaimers that use a rotating drum fitted with a series of
buckets along its length. The drum spans the stockpile and is mounted on rails on
both sides of the stockpile. Drum reclaimers are a high-capacity reclaimer for
blending materials such as coal, limestone, ore, etc. They are working in one or two
reclaim directions. The bulk material is received via the rack of the rotating drum
with buckets and is transferred onto the discharge conveyor belt that is mounted
within the drum (Foerdertechnik, 2010).
3.3.3.3 Stacker-Reclaimer

A stacker-reclaimer is used to stack the material in a stockyard and to reclaim the material
from a stockpile. Because stockyards may take different configurations depending on the layout
of the port and plant equipment, the equipment must be designed to make the most of the limited
space available (Kawasaki, 2016). There are two categories for a stacker-reclaimer:

1. Bucket Wheel Stacker-Reclaimer. A bucket wheel stacker-reclaimer is very similar to the

traveling stacker in the stockout mode. The stacker-reclaimer is equipped with a bucket
wheel at the end of the boom for the reclaim mode The boom conveyor is also reversible for
stockout versus reclaim. The counter-weighted, cantilevered boom conveyor is supported on
a gantry that travels on a set of rails. The stacker-reclaimer boom is capable of a luffing
motion and is utilized in both the stockout and reclaim modes. The two types of bucket
wheel-stacker reclaimer are the trench type and the slewing type (Black & Veatch, 1996).

a. Trench Type Stacker-Reclaimer. The Trench type stacker reclaimer reclaims by

continuously traveling while the boom and rotating bucket wheel remain at 90 degrees
(1.5 rad) to the track. The bucket wheel reclaims the material benches as the boom is
lowered after each travel distance. A typical trench type stacker reclaimer with a 50 ft.
(15.24 m) boom can reclaim 25 tons/ft. (74 metric tons/meter). The newer trenchers also
slew the boom to 45 degrees (0.8 rad) from the track and increase the reclaim capacity
to 30 tons/ft. (89 metric tons/meter) by reclaiming additional coal next to the track. This
reclaim rate of 25 to 30 tons/ft. (74 to 89 metric tons/meter) is from the total stockout
capacity of 40 tons/ft. (119 metric tons/meter) (Black and Veatch, 1996).

Trench type stacker reclaimer is ideal for installations with low-volume, high-active
storage pile capacities between 30,000 and 60,000 tons, where reclaiming operations are
accomplished by a longitudinal pass through the pile. Reclaim rates usually vary from
2,000 to 4,500 tons per hour (Black and Veatch, 1996).
 Figure 3.X Trench Type Bucket Wheel Stacker-Reclaimer

b. Slewing Type Stacker Reclaimer. The slewing type stacker reclaimer reclaims by
continuously slewing the boom from 90 to 30 degrees (1.5-0.5 rad) to the track and back
while traveling in short increments between each slew motion. The bucket wheel
reclaims the material in benches similar to the trencher. A small size slewing type
stacker reclaimer with a 95 ft. (29m) boom can reclaim 75 tons/ft. (223 metric
tons/meter). A large size slewing type stacker reclaimer with a 185 ft. (56.4 m) boom
can reclaim 240 tons/ft. (714 metric tons/meter). These reclaim rates of 75 and 240
tons/ft. (223-714 metric tons/meter) are from the total stock out capacity of 110 and 310
tons/ft. (327 and 923 metric tons/meter) respectively (Black and Veatch, 1996).

Slewing type stacker reclaimers are typically used where large quantities must
be readily available, where the blending of grades of materials is required or where
available yard length is limited. These machines feature boom lengths up to 220 ft. (67
m) and stacking and reclaiming rates up to 6,000 tons/hour for coal and 8,000 to 10,000
tons per hour for iron ore. While offering maximum flexibility, slewing type machines
also help lower the unit costs involved in the handling of bulk materials. The slewing
type stacker reclaimer utilizes motion for operating in the pile during stacking and
reclaimers (Black and Veatch, 1996).
 Source: Black & Veatch,
1996Source: Black & Veatch, 1996
Figure 3.X Slewing Type Stacker-Reclaimer

2. Portal Stacker – Reclaimer. A portal stacker-reclaimer, is similar to the traveling stacker in

the stockout mode. The boom is supported from a portal structure that spans the storage pile
and travels on a set of rails, one on either side of the pile. A long pile, with a triangular
cross-section, is formed as the portal stacker - reclaimer travels. The boom supports the
chain and scraper blade assembly that is reversible for both stockout and reclaim operations.
Stockout of the material is accomplished by the boom also being equipped with a conveyor
that elevates the material to the discharge point of the boom. The material then free falls
onto the top of the pile. The boom is raised as the pile is formed to minimize the free fall
height. This method of stockout is most commonly used for moderate to small power
stations where enclosed storage is required or for a small plant for both coal and limestone.
A typical portal stacker-reclaimer with a 100-ft (30.5-m) boom can stockpile a pile 40 ft
(12.2 m) high. It stockpiles 50 tons/ft (149 tonnes/m) of coal or 85 tons/ft (253 tonnes/m) of
limestone (Black & Veatch, 1996).

3.3.3.4 Stacker-Reclaimer Selection

Selection of the most appropriate stockout system is based on the unloading system
selected, blending requirements, enclosed storage requirements, and economic considerations.
Alternate types of outdoor stockout equipment for coal or limestone include a fixed boom
conveyor, radial stacker, traveling stacker, bucket wheel stacker-reclaimer, and an elevated
reversing shuttle conveyor (Black & Veatch, 1996).
 The comparison of the parameters of the two stacker-reclaimer is shown in the Table below.

Table 3.X Stacker-Reclaimer Specifications Comparison

Specifications
Parameters
Trench Type [1] Slewing Type [2] Portal Type[3]
Bulk Weight 1.05t/m3 N/A N/A
Stacking Rate 5400 tph 6000 tph 1000-2000 tph
Reclaiming Rate 3600 tph 5000 tph 1000 tph
Belt Width 1829 mm 1800 mm N/A
Boom Length 17.5 m 60 m 60 m
Rail Length N/A 78 m N/A
Travelling Speed 28 m/min Not specified 2.86-15 m/min
Belt Speed 5.1 m/s 3-6 m/s N/A
Rail Gauge 6.1 m 12 m N/A
Stacking Height 13 m 24 m N/A
Specific Power Not specified
0.55 kWh / ton 0.75 kWh / ton
Consumption (Low)
Source: [1] Krupp Robins; [2] Sinospare; [3] Koin Jaya

The selected stacker-reclaimer was chosen by the designers based from the parameters
that will help design the coal storage such as the stacking height, boom length, rail gauge, and
rail length. Based on the data above, the slewing type stacker-reclaimer is more suitable for the
power plant. It has a boom length of 60 m compared to the trench type with only 17.5 m, this
will be easier to use for a large are of coal storage. The stacking height of the slewing type is 24
m compared to the trench type with only 13 m. The selected stacker-reclaimer has a rail gauge of
12 m, while the trench type has 6.1 m.
3.3.4 Coal Storage

Storage is necessary at several points in the coal supply chain because coal is transported
in batches rather than moved continuously through a network. The supply chain must
accommodate surges and lulls in demand at the mine, at the origin and receipt dock or port, and
at the end user such as power plant (Kaplan, 2019).

The coal storage area includes both active and reserve coal storage. Active coal storage
implies the reclaiming and combustion of coal that has been stored for only a relatively short
time, usually less than a week. Coal from an active coal storage pile is usually reclaimed without
the use of mobile equipment. Normally, a power plant has an active storage capacity of 3 days at
the maximum burn rate of all units. The 3 days are increased or reduced depending on coal
sources, transportation modes and distance, climate, and plant availability requirements. For a
plant with multiple coal sources and delivery modes, a short haul distance, and average climate
conditions, the active storage requirement relates to a capacity of 3 days or less (Black & Veatch,
1996). The following Table presents the requisite design parameters for calculating coal storage
capacity

Table 3.X Design Parameters of the Coal Storage

Equipment Slewing Stacker-Reclaimer Type

Stockpile Height 24 m
Rail Length 78 m
Boom Length 60 m
Rail Gauge 12 m
Mass of Coal per 30 days 124095.98 Mtons
Coal Density 1300 kg/m3

3.3.4.1 Calculation of Storage Area

The reserve storage pile is a long-term storage area that provides an emergency supply of
coal for the power plant in the event of an interruption of coal shipments. The reserve storage
pile usually holds a 60- to 90-day supply at 65% to 80% of maximum bum rate (Black & Veatch,
1996). The required mass of coal per month is 124095.98 metric tons. There should be an
additional 9.86% for emergency response in the storage are (Morse, 1953). Since the coal is sub-
bituminous coal, the density should be taken as 1300 kg/m3 (Wood et al., 1983). The computation
of the volume of the coal storage and coal pile is shown below:

(Coal Consumption per month) (No. of Months) (emergency response)

Volume of coal storage =
coal density
Mtons
(124 095.98 ) (2 months) (1 + 0.0986) (1000
Month
kg
= ¿
Mton
kg
1300 3
m

Volume of coal storage = 209741.30 m3

Based from the computation above, the volume of the coal storage is 209741.30 m3. To
obtain the volume for each coal pile, the calculation is shown below.

Volume of each coal pile = Atriangle x L

1
= BxHxL
2
1
= (60 m)(24 m)(78 m)
2
Volume of each coal pile = 56 160 m3

It was determined that each pile has a volume of 56 160 m 3. To determine the number of
coal piles needed, the total volume of the coal storage must be divided into the volume of each
coal pile. The calculation to know how many coal piles are needed is shown below.

Volume of coal storage

No. of Coal pile =
Volume of each pile
209741.30
=
56 160 m3
No. of Coal pile = 3.73 ≈ 4 piles
The coal storage has a volume of and can be divided into 4 piles. Table 3.X shows the
summary of storage area capacity.

Table 3.X Summary of Coal Storage Area

Parameter Value
Coal Consumption for 30 days 124 095.98 Mtons
Volume of coal storage 209741.30 m3
 Volume of each coal pile 56 160 m3
Number of coal pile 4

For the coal yard layout, the design parameters that are needed are the rail length and
boom length of the stacker-reclaimer. Since the operational length and width of a standard tractor
or backhoe is 6.1 m x 2 m, assume an additional 15 m permitted for highway and sprinkler
system. (KTC, 2012). Figure 3.X below shows the coal yard layout for the proposed plant.

Figure 3.X Coal Yard Layout

The computation below shows the required dimensions of the coal storage:

Total Area of the Storage ` = Total Length x Total Width

Total Area of the Storage = 201 m x 162 m

1 hectare
= 32 562 m2 ×
10 000 m2
Total Area of the Storage = 3.25 hectares

Thus, the total area of the coal storage is 3.25 hectares.

3.3.5 Coal Crusher

 In general, the size of the coal received at power plants is typically 4 in. (0.10 m) or smaller.
The size required for the pulverizers used with most pulverized coal steam generators is VA to
l'/2 in. (0.03 to 0.04 m). This requires the reclaimed coal to be reduced by crushing before it is
transported to the unit silos (Black & Veatch, 1996). In general, coal crushers are categorized
into two types and three types of primary crushers. Primary coal crusher is used for larger coal
size. The primary coal crushers may be of different types such as: (1) coal jaw, (2) coal hammer,
and (3) ring granulator. The next crusher is the Secondary coal crusher, it is used when the coal
coming from the supplier is large enough to be handled by a single crusher. The primary crusher
converts the feed size to one that is acceptable to the secondary crusher (Basu et al., 2015).

3.3.5.1 Types of Primary Coal Crusher

As Basu (2015) stated, primary coal crushers can differ in types such as the coal jaw, coal
hammer, and ring granulator.

1. Coal Jaw Crusher - Jaw crusher is one of the most commonly used equipment in mining
machinery. Jaw crusher is generally used for primary crushing, which has many
advantages, such as high crushing ratio, high capacity, cubical final product size, simple
structure, easy maintenance and so on (Shanky-Machinery, 2021). The primary crushing
of hard rocks without rubbing and with the least amount of dust is done by jaw crushers.
Jaw crushers used to crush materials such as coal, granite, basalt, river gravel, bauxite,
marble, slag, hard rock, limestone, iron ore, magazine ore within a pressure resistance
strength of 200 Mpa (Basu et al., 2015). The Figure below shows the actual photo of a
coal jaw crusher.

Source: htjxchina, 2024

Figure 3.X Coal Jaw Crusher
2. Coal Hammer Crusher - Hammer crusher can crush materials with different sizes into
equal particle, which favors the next procedure. The material crushed by the Hammer
Crusher (Hammer Mill) through the collisions between high-speed hammer and
materials. Hammer crusher (hammer mill) is applicable for various hard and fragile
materials, such as limestone, coal, salt, gypsum, alum, brick and tile, etc. The crushing
compressive strength of materials should not be in excess of 150Mpa (dlodha, 2014).
Figure 3.X shows the photo of a coal hammer.

Source: Agico cement, 2024

Figure 3. X Coal Hammer Crusher

3. Ring Granulator - The crusher works best with compressive strengths under 150 MPa.
After entering the crusher, the high-speed revolving ring hammer crushes the material,
and the crushing plate breaks the first broken material. When crushed material falls
between the sieve plate and the ring hammer, it is sheared, rolled, and ground to the
appropriate particle size and discharged from the grid hole of the sieve plate. A little
amount cannot be broken. The centrifugal force throws material into the iron removal
chamber, which is periodically removed. A fixed screen grid hole at the bottom controls
discharges particle size (Wang et al., 2019).

Source: Indiamrt
Figure 3. X Ring Granulator Crusher
3.3.5.2 Coal Crusher Selection

The designers evaluate the specifications of the aforementioned coal crushers in order to
choose the most suitable coal crusher for the proposed power station. In the context of a fluid-
bed combustor, the dimensions of the coal particles lie within the range of coal sizes specified for
both pulverized-coal and stoker firing methods. Coal is comminuted to a particle size smaller
than 1/4 inch (6.35mm) and afterwards introduced into the lower section of a fluidized bed
furnace (Woodruff et al., 2004). The following Table presents the specifications of the coal to be
crushed.

Table 3.X Size Specifications of the Selected Coal

Parameter Value
Raw Size 50 mm
Product Size 3-6 mm [1]
Source: [1] MPC, 2021

The Table below shows the specifications of the Coal crushers to be evaluated.

Table 3.X Coal Crusher Specifications

Parameters Jaw Crusher[1] Hammer Crusher[2] Ring Granulator[3]

Feed Size Max. 50 mm Max. 100 mm Max. 100 mm
Product Size 6 mm 5-6 mm 0.5 mm
Capacity 85 tph 100 tph 50 tph
Coal, iron ore, Mn Coal, gangue, coke,
Coal, Limestone,
Feed Materials ore, Chromite ore, slag, shale, limestone,
Gypsum, Aluminum
Rock, Mg ore magnetic iron ore
Power Consumption 0.58 kWh/ton 0.250 kWh/ton 0.42 kWh/ton
Source: [1] Weir Mineral; [2] AGICO Group; [3] ANDE Metallurgical Machinery Equipment Co., Ltd and
IndiaMart

Based on its capacity and product size, the Hammer crusher was chosen by the designers.
Coal used in CFB is crushed to a size of approximately 3 to 6 mm (MPC, 2021). With a capacity
of 100 tons per hour, the hammer crusher is suitable because its product size is 5 to 6 mm. It can
produce more than the other two crushers combined, and it uses the least amount of power. Fuel
from the coal silo will be fed into the furnace using a product size of 5–6 mm.
3.3.5.3 Number of Coal Crushers

Once type of coal crusher has already been determined, the number of coal
crushers required should also be determined. The calculation below indicates how many
coal crushers are required for the power plant design.

Coal Consumption per day

Number of Coal Crushers =
Avg. Coal Crusher Capacity

( 4136.53 Mtons
day )( 3 boilers 24 hours )
1
)( 1 day

=
(70 Mtons
hr )
Number of Coal Crushers = 0.82 ≈ 1 Coal Crusher per boiler

Considering the design parameters and the energy consumption, the selected coal
crusher is the hammer crusher. The result for the computation was 0.82 which is
approximately one (1) coal crushers is needed for each boiler but since the fluidized bed
power plant has three (3) boilers, three (3) coal crushers are needed for the whole plant.