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Stackers

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Lipsa Mahapatra
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30 views9 pages

Stackers

Uploaded by

Lipsa Mahapatra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Stackers & Reclaimers

• Since bulk materials arrival time at a plant is much shorter as compared to their consumption time, they require
to be stocked/stored. Due to this, stackers are needed to create stockpiles of the bulk materials.
• Buffer storage of the bulk materials in the stockpiles is also necessary to take care of any disruptions in the
transport system or in the mines due to which material cannot be received at the plant on such days. The
capacity of the stockpiles ranges from 7 days to 45 days requirement of the plant.
• The material so stored needs to be retrieved (reclaimed) to suit its gradual consumption in the plant. Therefore,
stock yard needs reclaimer machines to reclaim the material.
• Since the stackers and reclaimers have to store and reclaim material over a long distance, they are mounted on
rails.
• If the storage capacity is less (for example, 50,000 T coal), the stockpile can be formed by telescopic chute
arrangement and by dozing (using bulldozer).
• Telescopic chutes are used to minimize the height of material fall into stockpiles to minimize dusting. The
telescopic sections are usually cable-connected in such a manner that a winch can successively lift the sections of
the chute. The lower end of the chute is always kept just clear of the top of the stockpile to reduce dust
generation. The reclaiming can be carried out by dozing the material in to a ground hopper.
• Stackers and reclaimers are also required for homogenization / blending of bulk materials.
Stockpile Layouts

• The longitudinal arrangement allows easy future expansion but requires more space.
• The circular arrangement basically prevents any future expansion but has a more compact footprint.
• Longitudinal stockpile arrangement is used for high storage capacity.
• To protect the material from wind and rain and to avoided the problems associated with them, many times the
entire stockpile and the stacker and/cum reclaimer machines are covered within a shed.
Stacking Methods
The most commonly used stacking methods for making longitudinal stockpiles are Cone Shell, Chevron and
Windrow. Basically these methods consist of stacking a large number of layers on top of each other in the
longitudinal direction of the pile.

1. Cone Shell

In the Cone Shell method, the pile is formed by depositing material in a single cone from a fixed position. When
this conical pile is full, the stacker moves to a new position and a new cone is formed against the shell of the
first one. This process continues in the longitudinal direction of the store until the stockpile is complete.

2. Chevron In the Chevron method material is deposited by the stacker moving to and fro
over the centre line of the pile. However, the Chevron stacking method causes
segregation of the material with fine particles in the central part of the pile and
coarse particles on the surface and at the bottom of the pile. To ensure proper
blending a Chevron pile must therefore be reclaimed from the face of the pile,
working across the entire cross section.
3. Windrow
In the Windrow method, material is deposited from a number of positions across
the full width of the pile. This method needs a luffing and slewing stacker. The
Windrow method prevents segregation and ensures more even distribution of fine
and coarse particles across the pile. The Windrow method is preferred in cases
where the reclaimer is only operating in one part of the pile cross section at a time.

4. Strata The Strata method needs a luffing and slewing stacker. In the Strata stacking
method, the stockpile is built up in inclined layers. The stacker builds the first layer
travelling along the storage area with its boom at a low elevation. The stacker then
moves towards the stockyard centre in pre-set steps while gradually lifting the
boom. The result is superimposed inclined layers, matching the angle of repose of
the bulk material and providing a good blending as the reclaimer cuts into each of
the many layers.
In view of above, if no blending is required, Cone Shell, the simplest stacking method will be chosen. It requires no
slewing mechanism/gear in the stacker and simplifies the movement of the stacker during stacking. If blending is
necessary, the Chevron and Windrow methods are used. Chevron is the preferred choice, as it does not require
slewing mechanism in the stacker.
Stackers
• A stacker is chosen based on the stockpile layout, the material properties and the required stacking method.
• For example, a stacker must reach the whole cross section of the pile, if Windrow stacking is required. For
Chevron or Cone Shell stacking, it is enough to reach the center of the pile only.
• The stacking process can be done by a simple tripper car (overhead) or it can be a stacker equipped with a
travelling and luffing or luffing and slewing mechanism.

Following are the three basic movements in a stacker:


Travelling - Bogie move the machine on rail track along the stock/storage yard.
Luffing - This is the vertical up/down movement of the boom mostly powered by two hydraulic cylinders.
Slewing - This is rotation of boom around its central axis to discharge the material on the stock yard where required.
Stacker Construction
• A stacker includes a tripper and main body.
• Tripper and main body are mounted on bogies to move the machine on rail track along the stock/storage yard.
• The main body includes stacking boom conveyor.
• The stationary yard conveyor passes through tripper and discharges material on to the boom conveyor.
• The boom conveyor discharges the material on the stock yard to form the stockpile.
• The luffing mechanism of a stacker is driven either by a hydraulic drive unit or a winch.
• Luffing stacker (stacker without slewing mechanism) makes stockpile in Chevron and Cone Shell formation.
• Luffing and slewing stackers are used to make stockpiles on both sides of the machine. In addition to Chevron
and Cone Shell type of formations (due to luffing capability), they can make stockpile in Windrow and Strata type
of formations also (due to slewing capability).
• Twin boom stackers are having two booms, one on each side of the machine with luffing arrangement. Two
booms make it possible to form stockpiles on both sides of the machine without the slewing mechanism.
• The tripper car and yard conveyor is often equipped with a bypass arrangement, use of a bifurcating chute and a
diverter/flap gate, that enables material to bypass the stacker boom and continue along the yard conveyor (to
meet plant requirement).
• The material conveyed from the tripper is discharged on the bifurcating chute. The chute has two legs, one for
directing the material towards the boom conveyor during stacking and the other for discharging the material in
to the central chute for bypassing the boom conveyor (direct loading to the yard conveyor).

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