Rimberio University

BULK
HANDLING SYSTEMS
By Aaron Loeb | 2025
 CONTENTS
1. Basic principle of material handling in mining
2. Benefits of bulk material handling
3. Classification of material handling equipments
4. Global and indian scenario of bulk handling
5. Selection of suitable systems
6. Stacking, blending and reclaiming
7. Stockpiles,silos and bunkers
8. Wagon loading and weigh bridges
9. Segregation of materials
10. Railways slidings for bulk transports
 Introduction
Bulk handling systems are designed to transport, store,
and manage large quantities of loose, unpackaged
materials like grains, coal, ores, chemicals, or sand.
These materials are often referred to as bulk materials
because they are not in containers, but in large
quantities that require special equipment to move
efficiently.

What is Bulk Handling?

Bulk Handling refers to the movement of large volumes of
loose materials from one location to another, often in
industries like mining, agriculture, and construction.
These materials can be solid (like grains, coal, or cement)
or liquids (like chemicals or oils) that need to be handled in
bulk.
 Basic principle of material handling in mining

Efficiency Safety
Faster Movement: The goal is to move materials Protecting Workers: Safety is a top
quickly and easily from one place to another, using priority. Workers should be trained to use
the right equipment such as conveyors, trucks, or equipment properly, and safety gear must be
loaders. worn to prevent accidents.
Reducing Delays: Efficient systems ensure that Safe Equipment: Machines and tools need
mining operations continue without unnecessary to be maintained to prevent malfunctions that
interruptions, saving time and costs. could lead to injuries.

Handling Bulk Materials Minimizing Spillage and Losses

Types of Materials: Mining often involves large Preventing Waste: Spillage means losing valuable
quantities of bulk materials, such as ores and coal. material, so it’s important to handle and transport
These materials are heavy and may be dusty, wet, materials carefully. Properly designed containers and
or difficult to handle. transport routes can help reduce spills.
Special Equipment: To move bulk materials Proper Equipment Maintenance: Regular
safely, equipment like bulldozers, trucks, maintenance of machinery helps avoid breakdowns that
conveyors, and cranes are used. could lead to material losses.
 Benefits of bulk material handling

Reduces Manual Labor Increases Productivity Enhances SafetyAdd a subheading

Bulk material handling With machines doing the Automated systems

systems (like conveyors or heavy lifting, materials reduce the risk of workers
automated machines) can can be moved faster getting injured while
move materials without and more efficiently. handling heavy or
needing people to do it by dangerous materials. It
This means more work
hand. This makes work also lowers the chances
gets done in less time,
easier and reduces the
leading to higher of accidents related to
need for workers to lift
productivity. manual handling tasks,
heavy loads.
keeping workers safer.
 Goals Classification of material handling
equipments

Conveyors Stackers
Purpose: Conveyors are machines used to move Purpose: Stackers are used to load and unload
materials from one place to another. materials and stack them in piles or rows.
Types: Belt conveyors, roller conveyors, and screw Application: Used in industries like steel, mining, and
conveyors. warehousing to stack goods such as pallets or bulk
Application: Often used in assembly lines, warehouses, materials
and airports to move goods automatically.

Reclaimers Hoppers Crushers

Purpose: Reclaimers are used to Purpose: A hopper is a container that Purpose: Crushers are used to break
holds and dispenses materials, typically down large materials into smaller,
retrieve stored bulk materials (like coal
bulk materials like grain, gravel, or coal. manageable sizes.
or grain) from stockpiles.
Application: Used in industries for Application: Used in mining,
Application: Common in industries that storage and controlled release of construction, and recycling to crush
store large quantities of materials, such materials to conveyors, crushers, or rocks, ores, and other hard materials.
as mining, power plants, and ports other machinery.
 Mobile vs Fixed Equipment

Mobile Equipment:
Definition: Can be moved from one location to another.
Examples: Mobile stackers, mobile reclaimers, mobile crushers, and forklifts.
Benefits: Flexible, can be relocated to different areas as needed.
Applications: Often used in construction sites, mining, and port operations.
Fixed Equipment:
Definition: Stationary and installed in a permanent location.
Examples: Fixed conveyors, hoppers, and crushers.
Benefits: Usually more durable and can handle large, continuous operations.
Applications: Used in manufacturing plants, warehouses, and processing plants.
 DiscussionsGlobal and indian scenario of bulk
handling

Global Scenario of Bulk Handling

Automation: Reducing human effort and errors.
AI: Helping to plan better and avoid breakdowns.
Robotics: Ensuring safe and accurate handling.

Indian Scenario of Bulk Handling

Old equipment: Many systems are outdated and inefficient.
Poor infrastructure: Ports, railways, and warehouses
are not fully equipped for smooth handling.
Slow adoption of technology: Automation and AI are used
less compared to global standards
 Selection of suitable systems
1. Material Type:
The system should match the types of material being handled (e.g., grain, coal,
cement).
Consider properties like size, weight, and whether the material is fragile or
hazardous.
2. Handling Distance:
For short distances, simpler systems like conveyors might work.
For longer distances, advanced systems like pneumatic conveyors or automated
trucks may be better.
3. Cost-Effectiveness:
The system should provide good performance while staying within the
budget.
Consider not just the initial cost but also maintenance and energy expenses.
 Selection of suitable systems
1. Material Type:
The system should match the types of material being handled (e.g., grain, coal,
cement).
Consider properties like size, weight, and whether the material is fragile or
hazardous.
2. Handling Distance:
For short distances, simpler systems like conveyors might work.
For longer distances, advanced systems like pneumatic conveyors or automated
trucks may be better.
3. Cost-Effectiveness:
The system should provide good performance while staying within the
budget.
Consider not just the initial cost but also maintenance and energy expenses.
 Stockpiles,silos and bunkers

1.Stockpiles 2.Silos 3.Bunkers

Purpose: Vertical storage for materials Purpose: Short-term storage, often for
Purpose: Open storage for large needing protection (e.g., grain or feeding materials directly into a
quantities of material. cement). process.
Design: Piles are formed on the ground, Design: Tall, cylindrical structures, often Design: Rectangular or hopper-like
often in outdoor areas. made of steel or concrete. structures, usually underground or
Storage Capacity: Depends on the area Storage Capacity: Moderate to large, semi-enclosed.
available; ideal for massive quantities. depending on size. Storage Capacity: Smaller than silos and
Reclamation: Done using loaders, Reclamation: Gravity-based flow or stockpiles.
conveyors, or reclaimers pneumatic systems for easy discharge. Reclamation: Screw feeders, belts, or
gravity-assisted discharge.

Efficient Reclamation Methods

Automated Reclaimers: For stockpiles, these machines
ensure quick and uniform material retrieval.
Pneumatic Systems: For silos, they use air pressure to
move materials efficiently.
Feeders: For bunkers, they provide controlled material
flow into the production process.
 Wagon loading and weigh bridges

Wagon Loading Systems Weighbridges

1. Batch Loading: 1. Pitless Weighbridges:
Loads a fixed amount of material into Installed above ground.
wagons. Easy to maintain and ideal for
Suitable for precise and controlled locations with good drainage.
loading. 2. Pit-Mounted Weighbridges:
Common in industries requiring exact Installed at ground level with a pit.
material quantities. Space-saving and suitable for places
2. Continuous Loading: with limited area.
Material flows continuously into 3. Mobile Weighbridges:
wagons. Portable and quick to install.
Ideal for high-volume operations Useful for temporary sites or locations
where speed is important. with changing needs.
 Stacking, blending and reclaiming

1. Stacking:
Materials are arranged in piles for storage.
Helps in organizing bulk materials for easy access.
2. Blending:
Different materials are mixed to maintain uniform quality.
Ensures consistent performance in production processes.
3. Reclaiming:
Materials are retrieved from stacks for use.
Ensures a steady supply without interruptions.
Equipment Used
Stackers: Used to build and arrange material piles efficiently.
Blending Systems: Mix materials for consistent quality.
Reclaimers: Retrieve materials from stacks and feed them into the production process.
Thank You