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Methodology to Calculate the Effective Reclaiming Capacity of Rail-Mounted

Boom-Type Bucket Wheel Reclaimer and Stacker/Reclaimer

Article  in  Bulk Solids Handling · April 2004

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Dragan Komljenovic Carsten Drebenstedt

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D. Komljenovic, J. Paraszczak, K. Fytas, Canada and C. Drebenstedt, Germany

Methodology to Calculate the Effective

Reclaiming Capacity of Rail-Mounted
Boom-Type Bucket Wheel Reclaimer
and Stacker/Reclaimer

Summary
This paper focuses on the methodology to cal-
culate the effective reclaiming capacity of rail-
mounted bucket wheel reclaimers, and
stacker/reclaimers, for large-scale raw bulk ma-
terial handling systems. Due to considerable
gaps in the theory on this subject, a principal ob-
jective of the work presented here was to de-
velop a methodology destined to determine re-
claiming capacity of these machines. It reflects
the relationship between the characteristics of
the equipment and the parameters associated
with its work environment. A function concerning
the rule of the boom-slewing motion was de-
fined. It was based on the particular shape of
stockpiled material and the digging geometry of Fig. 1: Rail-mounted bucket wheel stacker/reclaimer with a slewing boom [21]
the machines. This function was subsequently
employed as a basis to work out a precise methodology for cal- these operations has a considerable impact onto prices of final
culating the effective reclaiming capacity of the equipment products. Therefore, bulk solids handling systems ought to be
analysed. Successful validation of the model developed was per- efficient, reliable, highly productive and must enable a good ma-
formed for the Quebec Cartier Mining (QCM) port facilities in Port terial flow, at the least cost. This requires more efficient reclaim-
Cartier. The paper concludes with some possible applications of ing and stacking machines.
the results achieved in this study.
The equipment employed to handle raw bulk materials in stock-
yards is referred to as a reclaimer (reclaiming operation only),
and/or stacker/reclaimer (both functions: stacking and reclaim-
1 Description of the Problematic and ing). The most frequently used ones are the rail-mounted boom-
Objectives of the Research type machines, such as a stacker/reclaimer shown in Fig. 1. To
simplify the text that follows, from now on these machines will
1.1 Introduction be referred to as “R&S/R”.
Handling and transhipment of bulk solid materials plays an im- During the reclaiming operation the bucket of such machines
portant role in modern economy. It is due, among other things, follows a 3D trajectory defined by a combination of three ele-
to steadily increasing volume of raw materials being transported mentary movements (Fig. 2):
from often remote mine sites on all continents to plants and fa-
cilities in both industrialised and industrialising countries. Cost of Fig. 2: Elementary movements of a bucket wheel reclaimer or stacker/reclaimer
in reclaiming operation [1]

DRAGAN KOMLJENOVIC, Ph.D., P.Eng., Production Advisor/Reliability Engineer,

Hydro-Quebec, 4900, boul. Bécancour, Bécancour (Quebec) G9H 3X3, Canada
Tel.: +1-819-298-2943 (Ext. 5032); Fax : +1-819-298-5092
E-Mail: komljenovic.dragan@hydro.qc.ca
Prof. Dr.-Ing., Dr.h.c. CARSTEN DREBENSTEDT, Professor in Opencast Mining
Technische Universität Bergakademie Freiberg, Mining Institute, Gustav-Zeuner
Str. 1, D-09596 Freiberg (Sachs), Germany. Tel.: +49-3731-393-373;
Fax: +49-3731-392-524; E-Mail: drebenst@mabb-tu-freiberg.de
JACEK PARASZCZAK, Ph.D., Full Professor, Dept. of Mining, Metallurgy and Materi-
als, Laval University, Quebec G1K 7P4, Canada; Tel.: +1-418-656-5103;
Fax: +1-418-656-5343; E-Mail: jacek.paraszczak@gmn.ulaval.ca
KOSTAS FYTAS, Ph.D., P.Eng., Full Professor, Dept. of Mining, Metallurgy and Ma-
terials, Laval University, Quebec G1K 7P4, Canada; Tel.: +1-418-656-5057;
Fax: +1-418-656-5343; E-Mail: kostas.fytas@gmn.ulaval.ca
Details about the authors on page XXX.

1 Vol. 24 (2004) No. 3 • bulk solids handling

 Reclaiming Capacity of Bucket Wheel Reclaimer

• rotation of the bucket around its own axis at speed vr,
• slewing of the boom around a vertical axis to a yard plane at
speed vzkr, and
• travel of the machine on rails parallel to the pile at speed vtr.
The stacking (stockpiling), as the second operation, can be car-
ried out only by stacker/reclaimers. The machine travels along-
side the stockyard where bulk material is stockpiled. Therefore,
one realizes the importance of developing a precise methodol-
ogy to calculate the performance of reclaiming and stacking op-
eration of R&S/R, as well as the creation of a selection criterion
for these machines.
1.2 Scope of the Work
At the early stage of the selection process of R&S/R, the
amount of information available is limited. Specifications pro-

Nomenclature
a distance between the travelling axis of the R&S/R and the tg acceleration time of the boom or the machine [h]
pile toe [m] tk digging time in a cut [h]
A area of an individual cut in a reclaiming operation [m2] tk(mod) total digging time in a module [h]
a1i distance between the travelling axis and the near bench tktot total digging time in a stockpile [h]
edge [m]
tm manoeuvring time of R&S/R in the reclaiming operation [h]
a2i distance between the travelling axis and the
far bench edge [m] tmtot total of all manoeuvring times in all modules of a stockpile [h]
a1p distance between travelling axis of the R&S/R and the near tod returning time of the machine [h]
bench edge, in the first reclaimed bench [m] tpd raising time of the boom [h]
ast distance between the travelling axis of the machine and the tpr advancement time of the machine [h]
stockpile-middle [m]
tr-st operating (reclaiming) time [h]
b0 cutting width at the slewing angle 00 [m]
tsp lowering time of the boom [h]
bβ cutting width at the slewing angle β [m]
ttr displacement (travelling) time of the machine [h]
c0 cutting depth at the slewing angle 00 [m]
Tcal total calendar time per year; Tcal = 8760 h
cβ cutting depth at the slewing angle β [m]
vkβ slewing speed of the boom at the slewing angle β [m/min]
D bucket wheel diameter [m]
vkβ1i slewing speed of the boom at the end of the interval 2 [m/min]
2d distance between the rails of the runway [m]
vkβ2i slewing speed of the boom at the end of the interval 3 [m/min]
dp width of the pile top flat [m]
vr peripheral speed of the bucket wheel [m/s]
dpc width of the pile top flat which is not still reclaimed [m]
vtr travelling speed of the machine [m/h]
di width of the pile flat in the bench i [m] min/max minimal/maximal slewing speed of the bucket wheel boom at
vzkr
dmp width of the pile top flat – full reclaiming block [m] the bucket [m/min]
Er bucket volume [m3] Vz reclaimed volume [m3]
gu maximal slewing acceleration/deceleration of the bucket X distance between the rotating centre (slewing axis) and the
wheel boom [m/s2] boom fixation [m]
g gravitational acceleration; g = 9.81 m/s2 Yk height of the boom fixation at the rotating centre of the ma-
Hmax maximal height of stockpiled material [m] chine [m]
H height of stockpiled material [m] α pile slope angle [°]
hi height of the bench i [m] αc angle of front slope [°]
Hr(g) maximal positioning height of the bucket wheel axis [m] αr angle between the bucket wheel and the boom in horizontal
plan [°]
Hri positioning height of the bucket wheel axis in the bench i [m]
β1i; β2i slewing angles of the boom - auxiliary variables [°]
Lk bucket wheel boom length [m]
βa1i angle of the interval 3 [°]
Lsr length of cutting edges in contact with material [m]
βva2i angle of the interval 4 [°]
n number of reclaiming benches in the pile
βua3i angle of the interval 2 [°]
ni discharge frequency of buckets [1/min]
βk1i angle of a maximal acceleration/deceleration of the boom -
nm number of modules in the stockpile inner bench side [°]
nr(i) number of cuts in a bench βk2i angle of a maximal acceleration/deceleration of the boom -
Qeff effective reclaiming capacity [m3/h] outer bench side [°]
Qex exploitation capacity (reclaiming rate) [m3/h] βmi angle of a maximal slewing speed of the boom [°]
Qt theoretical capacity (reclaiming rate) [m3/h] βt current slewing angle [°]
Qth technical capacity (reclaiming rate) [m3/h] βui boom slewing angle - near side of the block in the bench i [°]
r bucket wheel radius; r = D/2 [m] βvi boom slewing angle - far side of the block in the bench i [°]

Rki reclaiming outreach in the bench i [m] βvn boom slewing angle - far side of the block in the lowest
bench [°]
Rkn reclaiming outreach in the lowest bench (n) [m]
βtxy current slewing angle [°]
Sn stockpile width on the ground [m]
δi inclination angle of the boom in the bench i [°]
Snb reclaiming block width - full block [m]
ϕui contact angle between the bucket wheel and the reclaimed
Suk total stockpile width [m] material [°]

bulk solids handling • Vol. 24 (2004) No. 3 2

2mm luft lassen

vided by manufacturers specify (among others) linear dimen- slewing angle (Fig. 5). Therefore, a new guiding rule, reflecting
sions of the machine, and its theoretical output rate, usually ex- particularities of reclaiming should be developed.
pressed in tonnes per hour. It is more convenient to have the
This is an important issue, since an inaccurate assessment of
later parameter in m3/h because the bucket volume Er and the
design parameters of a R&S/R at the pre-select stage may have
number of bucket discharges per unit of time ni are usually
negative (and expensive) consequences for a future user. Unde-
known. In this case, the theoretical reclaiming rate is calculated
sired excessive capacity usually involves higher capital and op-
as follows:
erating cost, whereas insufficient one may put in jeopardy the
Q t = 60 · Er · ni (1) efficiency of the whole bulk material handling system.
The above value, however, is not the actual one that may be ex- A precise assessment of the effective reclaiming capacity be-
pected. Users should know the effective output rate (effective comes then one of the crucial points of the selection process.
capacity) for their planning schedule. This represents the actual
output of a reclaiming operation, and reflects influences of most
important factors, such as: 1.3 Principal Objective of the Work
• design parameters of the machine,
Given some drawbacks and gaps of currently used models de-
• geomechanical factors (properties of bulk material), and scribing the reclaiming function of rail-mounted bucket wheel
• technological parameters (block shape, mode of operation). reclaimer and stacker/reclaimer (R&S/R), it is justifiable to inves-
tigate a new approach.
These factors and influences may be presented in the manner
shown in Fig. 3. In this context, the study presented here will focus on develop-
ment of an accurate calculation methodology to determine
Calculation procedures (models) used currently for R&R/S are R&S/R reclaiming capacity.
those derived from Bucket Wheel Excavators (BWE) theory. BWE
operates in blocks, in which only the cutting depth changes with
an increasing slewing angle of the bucket wheel boom. This
change may be described by the following rule (Fig. 4): 2 Methodology to Calculate the
c β = c 0 · cos β (2) Effective Reclaiming Capacity of
Rail-Mounted Boom-Type
During the slewing operation, the height of cut remains un- Bucket Wheel Reclaimers and
changed. In order to compensate for this volume loss and to
keep the buckets full, the slewing speed of the bucket wheel Stacker/Reclaimers (R&SR)
boom should increase reciprocally:
Reclaiming operation modes may be classified into two cate-
v gories: a bench (more frequently used) or a modular-type (see
vkβ = k0 (3) Fig. 6) [12].
cos β
Fig. 5: Typical block shape in reclaiming operation [16]
This approach is not adequate in the case of a reclaiming oper-
ation carried out by R&R/S, where cutting height varies with the

Theoretical capacity Input

(main bucket wheel design parameters)

Transitional function Influence factors on effective capacity

- geomechanical/natural parameters
- technological parameters
Effective capacity - other design parameters
(Output)

Fig. 3: Influential factors on effective capacity

Fig. 4: Change of cutting depth with an increasing slewing angle [3]

3 Vol. 24 (2004) No. 3 • bulk solids handling

 2mm luft lassen

The principal type of a reclaiming operation is the block work.

There are two block shapes (Fig. 7):
• narrow block, and
• full block.
A combination of these two block types may also occur. Fig. 7
that illustrates geometrical relationships is a basis for a detailed
study presented below.

2.1.1 General Relationships

Fig. 6: Types of reclaiming mode [12]; a) bench-type b) modular-type
In order to develop a precise methodology of the reclaiming per-
formance of a rail-mounted bucket wheel R&S/R, it is necessary
to investigate and define the rules governing cut dimensions
variability both in horizontal and vertical plane. Following them,
the rule for a bucket wheel slewing speed would be defined.
This will enable determination of the transitional function (see
Fig. 3), and an exact calculation of effective reclaiming capacity.
This section gives equations for calculation of main geometrical
relationship between the linear parameters of the machine such
as: bucket wheel boom length, wheel diameter etc, and block
geometry.
Reclaiming outreach in the bench
According to design parameters of the machine and block di-
mensions, this parameter is calculated in the following manner:
R ki = Lk · cos δ i + X + r · cos α r · sinϕ ui (4)

2.1 Geometrical Relationships in External slewing angles

Block-Reclaiming Operation When the boom reaches the outer slope of the block, it is
As mentioned before, development of the adequate methodol- slewed at a certain angle from the travel axis of the machine.
ogy to calculate the effective capacity of a reclaiming operation This “external slewing angle” of the boom in the bench i, is de-
is the main objective of this research. fined in the following manner:
n
The first step consists of determining the main relationships be- (R kn − r · cos α r · sinϕ un ) · sinβvn − ∑ hj · cotα
j=i+1
tween the linear dimensions of the machine and the geometry of βvi = arcsin (5)
the bulk material block to be reclaimed. R ki − r · cos α r · sinϕ ui

Fig. 7: Block-types in a reclaiming operation; a) narrow block, b) full block

bulk solids handling • Vol. 24 (2004) No. 3 4

2mm luft lassen
Internal slewing angles
At the beginning of a bench at the inner side of the pile, the
bucket wheel boom is slewed at an angle called “internal slew-
ing angle”. It is also measured from the travel axis of the equip-
ment. Its numerical value is:
n
a + ∑ hj · cotα
βui = arcsin j=i+1
(6)
R ki − r · cos α r · sinϕ ui
2.1.2 Variation of the Digging Height
Due to the shape of the pile, the cutting height in a reclaiming
operation varies. If the pile cross-section is triangular, the cut-
ting height changes constantly in the first reclaimed bench. In
the case of a trapezoidal cross-section, this height remains con-
stant in the flat top area. Since this variation involves capacity
losses, it is important to determine a rule to adjust the boom
slewing speed to compensate for them.
Although some losses are inevitable due to a machine design
(for example due to a limit of maximum slewing speed), it is fea-
sible to minimize them. Fig. 8 will be used to determine the rule
of the digging height change. It is given as follows:
Fig. 8: Determining the cutting height change in reclaiming operation
5 Vol. 24 (2004) No. 3 • bulk solids handling
Height change within the sector βvi ≤ β2it < β2i (outer slope side)
βvi − βt2i
htβ2i = hi · (7)
βvi − β2i
Height change within the sector β1i ≤ β1it < βui (inner slope side)
βt1i − βui
htβ1i = hi · (8)
β1i − βui
If the machine is operating in a full block, the cutting height
changes only within the sector β1i ≤ β1it < βui (inner slope side)
and Eq. (8) should be used.
2.1.3 Digging Geometry and the Technical Capacity
In order to further develop the methodology to calculate re-
claiming performance, the technical capacity Qth and digging
geometry should be considered.
The former depends on natural (geomechanical) characteristics
of handled material, such as: digging resistance kL, swell factor of
material kr, and bucket fill factor kpu, cut dimensions (height,
depth, and width), and boom slewing speed.
 2mm luft lassen

Relationships concerning the technical capacity and digging
geometry, developed for BWE [3,8,13,14,15,19,22] remain ap-
plicable for the case of R&S/R.
In this study, they are adopted after a slight modification, and in-
tegrated into the methodology. The rationale of these relation-
ships may be found in the above mentioned references.
Besides technical capacity and specific digging force, the follow-
ing parameters of digging geometry are taken into consideration:
• Total length of cutting bucket edges Lsr;
• Optimal ratio between cutting depth and width (c/b)opt;
• Actual cutting depth and width, as function of the technical
capacity c0, b0;
• Peripheral digging force of the bucket wheel Pk;
• Optimal slewing speed at the beginning of a bench vk0.
There are two principal shapes of the bucket: trapezoidal and
semi-rounded. For more details, consult above mentioned ref-
erences.
speed” chart, see Fig. 9b. The slewing speed is defined by
angle βmi .
6. Maximal linear acceleration/deceleration in the far side pile
slope (Interval 6). The far side pile slope is defined by angle βk2i .
Intervals 4, 5, and 6 cover the area of the inner pile slope (D - A
in Fig 8). In order to maximise reclaiming capacity, it is necessery
to optimise the boom slewing speed in intervals 2, 3, and 4.
2.2.2 Rule of Slewing Speed Change by Intervals
Rule of slewing speed change at interval 2 (β1i < β1it ≤ βa3i )
Within this interval, both cutting depth and height vary. In order
to maintain constant capacity, the slewing speed of a bucket
wheel boom should then vary in a reciprocal manner. The for-
mula is as follows:
(β1i − βui ) · cos β1i
vβ1t
ki = vkβ1i · (10)
(βt1i − βui ) · cos βt1i

Fig. 9: Change of bucket wheel slewing speed

a) maximal design speed is reached
2.2 Rule of Slewing Speed Guidance b) maximal design speed is not reached
in a Narrow Block
The next stage consists in determining the rule for boom slewing
a)
speed guidance. As mentioned before, the dimensions of a cut,
dug by the bucket wheel, change in horizontal and vertical planes.
On a horizontal plane, the bucket wheel cuts a sickle shaped cut,
which changes accordingly to the rule given by Eq. (2), see Fig. 4.
On a vertical plane, the cut shape depends on the pile cross-
section (triangular or trapezoidal). The rule of change is defined
by Eqs. (7) and (8) (see Fig. 8).
Since the objective is to maximise the capacity, the boom slew-
ing speed ought to vary to compensate for changes in cut di-
mensions.
Its general form is as follows:
vkβ = ƒ(β, h) (9)

For the purpose of this research, an original methodology for

determining the rule of boom slewing speed change (guidance),
as a function of the cut-dimension variations mentioned above,
is developed.

2.2.1 Intervals of Slewing Speed Change

With regard to the above, and design limits of R&S/R, such as b)
the maximal slewing speed, and bucket dimensions, the follow-
ing intervals may be distinguished (see Fig 9):
1. Maximal linear boom slewing acceleration/deceleration in the
inner slope (Interval 1). The inner slope is defined by angle βk1i .
2. Automatic slewing speed regulation in the area where the cut-
ting height changes in the near-pile slope (Interval 2); intervals
1 and 2 cover the area of the inner slope marked by B - C in
u
Fig. 8. The near-pile slope is defined by angle βa3i .
3. Automatic slewing speed control in the area of a constant
cutting height (Interval 3), where only the cutting depth
varies. It is defined by angle βa1i . In Fig. 9, this interval is lo-
cated at the area C - D. If the pile has a triangular shape, this
interval is absent in the first /highest bench.
4. Automatic slewing speed regulation in the area where the
cutting height changes in the outer slope (Interval 4). The
v
outer slope is defined by angle βa2i .
5. Maximal slewing speed limited by maximal design limit of the
slewing speed (Interval 5). When such limit is not reached,
this interval will disappear from “Slewing angle - slewing

bulk solids handling • Vol. 24 (2004) No. 3 6

2mm luft lassen

Rule of slewing speed change at interval 3 (β2i < βi ≤ β1i ) A 1i

βa3i = βui + (19)
Within this interval, only the cutting depth varies. As the cutting (βa3i − βui )2 · COS2βa3i
height remains constant, the slewing speed is as follows:
where :
cos β1i
v kβi = vkβ1i · (11) v2kβ1i · (β1i − βui )2 · cos 2β1i
cos βi A 1i = (20)
7200 · gu · R ki
At the limit of this interval, the slewing speed reaches a value of:
cos β1i Determining angle βa2i , borderline between intervals 4 and 6
vkβ2i = vkβ1i · (12) (βvi < β2it < β2i )
cos β2i
This angle (see Fig. 9 b) defines a borderline between intervals 4
Rule of slewing speed change at interval 4 (βa2i < βi ≤ β2i ) and 6. If the interval 5 (maximal constant slewing speed, Fig. 9a)
exists, the calculation of this angle is different and will be shown
At this interval both the cutting depth and height vary. The slew- later. As in the previous case, one observes that the slewing
ing speed rule encompasses both variables: speed at the limit of interval 4 must be equal to that at the be-
ginning of interval 6. They coincide at point P. Therefore, the
(βvi − β2i ) · cos β1i
vβ2t
ki = vkβ1i · (13) equations become:
(βvi − βt2i ) · cos βt2i
v3 = gu · t6 (21)

Following this analysis, the optimal rule of the boom slewing

(βvi − β2i ) · cos β1i
speed change defined for intervals 2, 3, and 4 allows to achieve v4 = vkβ1i · (22)
maximal reclaiming capacity. In practice, if the reclaiming opera- 60 · (βvi − βa2i ) · cos βa2i
tion is automated, the guidance for the slewing speed is based on
both the engaged power of the motor installed the bucket wheel Since at the point P it is v3 = v4, the two equations can be com-
and on the material output recorded on the boom conveyor. pared and resolved with regard to t6:

2.2.3 Angles of Automatic Slewing Speed Guidance vkβ1i · (βvi − β2i ) · cos β1i
t6 = (23)
After the above analysis there still remain two transition points 60 · gu · (βvi − βa2i ) · cos βa2i
between intervals (borderlines) to be determined, namely: at the
border of intervals 1 and 2, as well as 4 and 5 (Fig. 9 a), or 4 and where:
6 (Fig. 9 b). Other borderlines have been determined in the pre- t6 slewing-motion time in interval 6 [s]
vious chapter.
In interval 6, the following is the equation of slewing motion:
Angle βa3i , borderline between intervals 1 and 2 (β1i < β1it < βui ) gu · t62
βk2i = (24)
This angle (see Fig. 9) defines a borderline between intervals 1 2 · R ki
and 2. Obviously, the slewing speed at the limit of the accelera-
tion (deceleration) interval 1 must be equal to that at the begin- The angle of the automatic speed control is calculated in the fol-
ning of the interval 2. They coincide at point Q (Fig. 9). Accord- lowing manner (Fig. 9b):
ing to these, it may be written as follows: βa2i = βvi − βk2i (25)
v1 = gu · t1 (14)
Integrating Eqs. (23) and (24) into Eq. (25), the following equa-
tion is obtained:
(β1i − βui ) · cos β1i
v2 = vkβ1i · (15) v2kβ1i · (βvi − β2i )2 · cos 2β1i
60 · (βa3i − βui ) · cos βa3i βa2i = βvi − (26)
7200 · gu · Rki · (βvi − βa2i )2 · cos 2βa2i
Since at point Q it is v1 = v2, these two equations can be com-
pared and resolved with regard to t1: It is also necessary to verify if the maximal design slewing speed
of the bucket wheel boom vzkr max has been reached or exceeded

vkβ1i · (β1i − βui ) · cos β1i at the angle βa2i.

t1 = (16)
60 · gu · (βa3i − βui ) · cos βa3i Note: Eqs. (19) and (26) should be solved by using a of numeri-
cal method.
where:
t1 motion time in interval 1 [s] 2.3 Digging Time in a Narrow Block Reclaiming
In interval 1 (maximal linear acceleration or deceleration), the Operation
equation of slewing motion is as follows:
Once the angles of automatic speed control are defined, it be-
g · t2 comes possible to determine the digging time of the bucket
βk1i = u 1 (17) wheel in a sickle cut.
2 · R ki
The angle of the automatic speed control is calculated in the fol- Digging time in interval 1 (defined by angle βk1i, see Fig. 9)
lowing manner (Fig. 9):
Slewing speed at point Q on the borderline between intervals 1
βa3i = βui + βk1i (18) and 2
(β1i − βui ) · cos β1i
Integrating Eqs. (16) and (17) into Eq. (18), the following equa- vQki = vkβ1i · (27)
tion is obtained: (βa3i − βui ) · cos βa3i

7 Vol. 24 (2004) No. 3 • bulk solids handling

 2mm luft lassen

This slewing speed at point Q is calculated using Eq. (10) by t 4i βa2i

substituting. t t
vkβ1i · (βvi − β2i ) · cos β1i · ∫ dt = 60 · R ki · βvi · ∫ cosβ 2i dβ2i
0 β2i
Acceleration (deceleration) time - digging time in interval 1 βa2i
t
−60 · R ki · ∫β 2i · cos βt2i dβt2i
vQki
t1i = (28) β2i
60 · gu

60 · R ki ·  (βvi − βa2i ) · sinβa2i − cos βa2i 

Digging time in interval 2 (defined by angle βua3i, see Fig. 9) t4i =   (34)
vkβ1i · (βvi − β2i ) · cos β1i
The slewing motion of the bucket wheel boom in this interval
(β1i < βt1i ≤ βa3i ) can be described by the following differential equa- 60 · R ki ·  (βvi − β2i) · sinβ2i − cos β2i 
−  
tion: vkβ1i · (βvi − β2i ) · cos β1i

(β1i − βui ) · cos β1i Eq. (34) represents the digging time in interval 4.
R ki · dβt1i = vkβ1i · (29)
60 · (βt1i − βui ) · cos βt1i
Digging time in interval 5
(if the latter exists, it is defined by angle βmi)
whose solution is the following:
t 2i β1i In interval 5, the slewing speed of the bucket wheel boom
reaches the maximal design value νmax
zkr (see also Fig. 9a). The
vkβ1i · (β1i − βui ) · cos β1i · ∫ dt = 60 · R · ∫ ki βt1i · cos βt1i dβt1i angle βmi is calculated as follows:
0 βa3i
β1i βm = βvi − βk2i − βm
ki (35)
−60 · Rki · βui · ∫ cos βt1i dβt1i
If an interval 5 exists, the angle βk2i defining the interval 6 (see
βa3i
Fig. 9a) is calculated according to the equation of slewing mo-
tion in this interval (6):
vmax
zkr
60 · R ki ·  (β1i − βui ) · sinβ1i + cos β1i  t5i = (36)
t2i =   (30) 60 · gu
vkβ1i · (β1i − βui ) · cos β1i
gu · t5i2
60 · R ki ·  (βa3i − βui ) · sinβa3i + cos βa3i  Rki · βk2i = (37)
−   2
vkβ1i · (β1i − βui ) · cos β1i
These equations give the following solution for the angle βk2i:
Eq. (30) represents the slewing motion time (synonymous to (vmax
zkr )
2

digging time) of the bucket wheel boom in interval 2. βk2i = (38)

7200 · gu · R ki

Digging time in interval 3 (defined by angle βa1i = β2i - β1i, see The digging time in interval 5 is expressed as:
Fig. 9)
60 · βmi · R ki
t5i = (39)
In this interval (β2i ≤ βi ≤ β1i ), the motion of the boom is described vmax
zkr
by the following differential equation:
cos β1i Digging time in interval 6 (defined by angle βk2i)
R ki · dβi = vkβ1i dt (31)
60 · cos βi It is the interval of maximal linear acceleration (deceleration) on
the outer side of a stockpile. In the absence of interval 5, the cal-
The solution is obtained in the following manner: culation is carried out according to Fig. 9b. The slewing speed
t 3i
at the point P has the following value:
β2i
(βvi − β2i ) · cos β1i
60 · R ki · ∫ cos βi dβi = vkβ1i · cos β1i · ∫ dt
0
vPki = vkβ1i ·
(βvi − βa2i ) · cos βa2i
(40)
β1i

and finally, the digging time in this interval: This represents slewing speed at the point P (border of interval
6) calculated by means of Eq. (13), by substituting.
60 · R ki The digging time is calculated in the following manner:
t3i = · (sinβ2i − sinβ1i ) (32)
vkβ1i · cos β1i
vPki
t6i = (41)
60 · gu
Digging time in interval 4 (defined by angle βva2i, see Fig. 9) If the interval of maximal slewing speed (interval 5) exists, this
time becomes:
The following differential equation describes the slewing motion:
vmax
t6i = zkr (42)
60 · gu
(βvi − β2i ) · cos β1i
R ki · dβt2i = vkβ1i · (33)
60 · (βvi − βt2i ) · cos βt2i Total digging time in a cut
The total digging time is given as the sum of individual digging
The solution is as follows: times by sectors. It is calculated as follows:

bulk solids handling • Vol. 24 (2004) No. 3 8

2mm luft lassen
6 Reclaimed volume of a cut in a narrow block
tk(i) = ∑t ji
j=1
With total digging time in a sickle cut determined, an important
stage in development of methodology to calculate the reclaim-
ing performance (capacity) is achieved.
Full block reclaiming operation
The rule of slewing speed guidance in a full block may be deter-
mined in a similar manner. In this case (see also Fig. 9b), a
R&S/R operates in the block where the cutting height on the
outer side of a pile remains constant. The variation in the cutting
height on the inner side of a stockpile follows the same pattern
as in a narrow block. Consequently, the slewing speed rule
changes must be defined. Intervals of slewing speed change in
a full block operation are determined using the same approach
as the one employed for the narrow-block reclaiming operation.
2.4 Effective Reclaiming Capacity
Effective capacity in reclaiming operation expresses a real out-
put of a system with a working reclaimer or stacker/reclaimer
(R&S/R). It depends on equipment design, technological para-
meters, as well as geomechanical properties and characteris-
tics of material handled. A general formula is as follows:
V In a bench-type of reclaiming operation (see also Fig. 6a), a
Q eff =
tk + tm
Eq. (44) represents the mathematical form of the transitional
function shown in Fig. 3.
The manoeuvring time tm accounts for manoeuvres of a given
machine in a digging cut, such as positioning a R&S/R during a
reclaiming operation. Depending on reclaiming mode (bench or
modular-type), this time is calculated differently. It does not de-
pend on the block-type (narrow or full block) in a reclaiming op-
eration.
At the beginning, a study concerning the effective capacity in a
sickle cut will be done. The next stage will consist in determin-
ing of effective reclaiming capacity in an entire stockpile.
2.4.1 Effective Reclaiming Capacity in a Cut
Reclaimed volume in a cut
It corresponds to the volume dug by the bucket wheel during a
slewing cycle – from the inner to the outer side of a stockpile. In
a narrow-block, it is calculated differently than in a full block.
Fig. 10: Plan for determining the manoeuvring time of a R&S/R in a modular re-
claiming type
9 Vol. 24 (2004) No. 3 • bulk solids handling
(43)
According to Figures 7a and 8, it may be written that:
R ki · hi · c β1i ·  sinβvi + sinβ2i − (sinβui + sinβ1i )
Vz(i) = (45)
2 · cos β1i
Reclaimed volume in a cut in a full block
Regarding figure 9b, reclaimed volume is as follows:
R ki · hi · c β1i ·  sinβvi − 0.5 · (sinβui + sinβ1i )
Vz(i) = (46)
cos β1i
After calculating the volume reclaimed in a cut, the manoeuvring
time must be determined.
Manoeuvring time in a cut
As previously mentioned, this is the time elapsed on manoeu-
vring motions of a machine in a digging cut (with digging time
excluded). It does not depend on the block-type (narrow or full
block) in a reclaiming operation. In the following, all components
of this time will be defined.
Manoeuvring time in the bench-type reclaiming operation
(44) R&S/R performs only one manoeuvre: an advance for a cutting
depth. It is calculated as follows:
c max (i)
tm(i) = tg + (47)
vtr
where:
cmax(i) depth of the machine’s advance (see Fig. 4).
c β1i
c max(i) = (48)
cos β1i
Manoeuvring time in the modular-type reclaiming operation
In a modular-type reclaiming operation (see also Fig. 6), the ma-
chine performs several manoeuvres (see Fig. 10).
The machine begins at the top of a stockpile by taking a cut.
The cut depth varies from case to case. At the completion of a
bench, the reclaimer moves back at the distance of the ad-
vance, plus an additional distance to clear the angle of a lower
bench face, and to assure a longitudinal terrace geometry which
is stable for reclaimed material. The boom is then lowered to the
next bench and a new reclaiming cycle begins. This sequence is
repeated for each bench in a reclaiming module. When the last
cut in the last bench (the lowest bench) has been completed,
the bucket wheel boom is raised to the highest (first) bench to
recommence a new cycle in a new module. According to the
above description, the total manoeuvring time is composed of
the following individual actions (see also Fig. 10):
• raising the boom tpd (between points 8 and 9);
• displacement of the machine ttr (see an explanation below);
• advance of the machine tpr (between points 1-2, 4-5, and 7-8);
• return of the machine tod (between points 2-3, and 5-6);
• lowering the boom tsp (between points 3-4, and 6-7).
These time components may easily be determined using Fig. 10.
Total manoeuvring time in a module
It is equal to the sum of all individual manoeuvring times:
 2mm luft lassen

n n−1
tm = ttr + tpd + ∑t pr(i) + ∑t od(i)
i=1 i=1
With total manoeuvring time expressed as a function of the type
of reclaiming operation, effective reclaiming capacity may be
calculated according to Eq. (44).
2.4.2 Effective Reclaiming Capacity
If a R&S/R operates in a bench-type of operation, its effective
reclaiming capacity in a cut can now be calculated according to
Eq. (44) where the cut volume is given by Eqs. (45) or (46). If,
however, a R&S/R carries out reclaiming operation of a modu-
lar-type, the effective reclaiming capacity of this machine in a
cut, may now be calculated according to Eq. (44). However, for
this type of operation, one talks rather about the effective ca-
pacity in a module than in a cut. The volume of a module may be
calculated as follows:
n Q eff = Q eff · T0
Vmod = ∑n r(i) · Vz(i)
i=1
The reclaimed volume depends on stockpile shape, digging
time changes with the block form (narrow or full), whereas ma-
noeuvring time depends on the reclaiming mode (bench-type or
modular-type operation). The formulas to calculate these para-
meters are developed above.
2.4.3 Reclaiming Performance in the Entire Stockpile
The methodology to calculate reclaiming performance deter-
mined previously takes into consideration the effective reclaim-
ing capacity of a R&S/R in a cut, or in a module. However, in
order to calculate a real output from a stockpile, the entire ma-
noeuvring and digging times concerning this stockpile, have to
be considered. The effective reclaiming capacity regarding the
entire stockpile is calculated as follows:
Vd
Q eff− st = 3600 ·
tr − st
where:
Vd volume of a stockpile [m3]
tr-st operating time in a stockpile [s]
n
2.5 Average Operational Performance Over
+ ∑t sp(i) (49) a Period of Time
i=2
It may be defined as a real performance of a R&S/R over a pe-
riod of time (usually one year) in actual local conditions. Besides
the factors related to effective reclaiming capacity (design, geo-
mechanical and technological), it may also be affected by orga-
nizational, climatic, subjective, market, etc. factors [15]. It may
be said that it depends on equipment availability and its con-
tributing factors (corrective and preventive maintenance, delays,
etc.), its utilization during working hours (operational delays,
statutory breaks, standby-time, etc.) as well as work scheduling
(working hours/shifts per day, workdays per year, etc.). An ex-
ample of equipment time split for a calendar year may follow a
pattern given in Fig. 11 [2].
In order to increase the efficiency of operations, delay times (op-
eration, maintenance) and idle time should be minimised. The
yearly reclaiming productivity (operational capacity) is given as
follows:
(52)
(50) where:
Qeff effective reclaiming capacity in a cut or in a module [m3/h]
To actual operating time of the machine per year [h/year]
The level of working and operating time depends on internal and
external conditions in a location:
• External conditions
- Needs for material handled
- Market fluctuation
- Input capacity from consumers (end-users)
- Frequency of reclaiming operation within a period of time
- Climate and weather conditions
- Type and properties of material handled
- Requested level of the environmental protection
• Internal conditions
- Synchronisation between material inflow and outflow
(51)
- Effective reclaiming capacity
- Organisational efficiency of reclaiming and maintenance
operations
- Stockpile layout
- Skills and training of the personnel

Fig. 11: Diagram showing basic equipment time elements

Total calendar time

Tcal
8760 hours

Working time Down time Idle time

Tw Tdw Tidl

Corrective and preventive

Operating delays Operating time Maintenance delays
meintenance time
Td To Tmd
Tr

Pure digging time Manoeuvring time Scheduled repair Unscheduled repair

Tk Tm Tsr Tdw

bulk solids handling • Vol. 24 (2004) No. 3 10

2mm luft lassen
These conditions may also vary from case to case and depend
on the location of a stockpile, as well as its purpose and organ-
isational level. Productivity can be improve by acting on internal
conditions and optimisation ought to be done at the local, inter-
nal, and organisational level. By determining relationships con-
necting the most important influence parameters (design, tech-
nological, natural, organizational), a R&S/R user or designer will
be able to improve performance of the machine in reclaiming
operation. Obviously, by increasing the performance (capacity),
a lower operation cost will be reached.
3 Model Validation on Site with a
Working Stacker/Reclaimer Example:
The Québec Cartier Mining Company
3.1 General Overview
The validation of the developed model was carried out at the
Québec Cartier Mining company (QCM), or more precisely at its
deep sea port in Port Cartier (province of Quebec, Canada).
General data have been obtained by courtesy of the communi-
cation department.
QCM is one of the leading producers of iron ore products in
North America, and exporter to the USA, Europe and Asia. It
operates an open-pit mine and a crusher/concentrator facility
capable of producing 18 million metric tonnes of iron ore con-
centrates annually at Mont-Wright, close to the city of Fermont
in Northern Québec. The company operates also a pellet-plant
in Port-Cartier, Québec on the north shore of the Gulf of St.
South side
44
21
5
84
Fig. 12: Typical stockpile cross-section
Fig. 13: Usual block shape during the reclaiming operation of the KRUPP machine at Port Cartier
11
Lawrence. Its annual production capacity is about nine million
metric tonnes of iron ore pellets. Iron ore concentrates and pel-
lets are subsequently loaded on ships and delivered to cus-
tomers. Pellets at Port Cartier stockpiles are handled by a
3ST46x140 stacker and a 3RP26x168 reclaimer, both from
Stephens Adamson. Iron ore concentrates are handled (stock-
piled and reclaimed) by a ThyssenKrupp’s Ldc (360x1000)/52
combined stacker/reclaimer. Stacking of concentrates is per-
formed using a chevron method, whereas a windrow method is
used for pellets. The latter is employed to avoid a segregation of
pellets having various corn sizes. Dimensions of a typical stock-
pile cross-section are shown in Fig. 12. The reclaiming opera-
tion is performed using a modular type operation.
3.2 Validation of the Calculating Methodology
Validation of the methodology has been performed for the
ThyssenKrupp machine. A typical shape of a reclaimed block is
shown in Fig. 13. It is necessary to mention that the machine op-
erates in a combined narrow/full block, modular-type reclaiming
operation. A usual depth of the machine advance in a module is
L = 15 m. However, other depth advances may occur as well.
Benches 1 and 2 are reclaimed in a narrow block, while
benches 3, 4 and 5 in a full block operation (see Fig. 13). This
way, a maximal efficiency of the reclaiming operation is assured.
Height of the first bench is usually 4.4 m (according to the rule
h1 ≈ 0.7·D), whereas that of the others 3.9 m.
For the conditions and dimensions specified above, effective re-
claiming capacity, calculated accordingly to a newly developed
North side
10
60
90
Vol. 24 (2004) No. 3 • bulk solids handling
 2mm luft lassen

methodology is Qeff = 766.2 m3/h. However, this capacity varies • geomechanical properties of bulk material (including its dig-
with a changing depth of the advance (see Table 1). It is due to ging resistance), and
a relative increase of manoeuvring time in total operating time. • technological parameters (block shape and mode of operation).
First, the influence of the main design and geomechanical para-
meters was defined. Subsequently, effective reclaiming capac-
3.3 Actual Achieved Performance of the Machines ity was determined. In addition to design and geomechanical
Records of operating performance exist for each machine at the parameters, the influence of technological factors should be
site for their whole operating life. taken into consideration. These are related to the digging and
manoeuvring time in a block. A complex mathematical analysis
Moreover, the records for the last 12 months, and the period of was used to develop an appropriate methodology for calculat-
time since the last overhaul of the machine, are displayed sepa- ing effective reclaiming capacity.
rately. All data is kept on a computer system which manages
Validation of the methodology performed on the operating
the entire operating data. Detailed information has been col-
ThyssenKrupp stacker/reclaimer at QCM’s Port Cartier harbour
lected from 1997 to August 2000. Tab. 2 gives reached results
facilities clearly confirms the applicability of this approach in ac-
of the KRUPP machine.
tual conditions. The difference between calculated and actual
Validation of the methodology performed on the KRUPP capacity, recorded over four years varies within a margin of ±1.5
stacker/reclaimer operating in Port Cartier (QCM), clearly shows %. Based on these results, it may be concluded that the devel-
the applicability of this approach in actual conditions. The differ- oped methodology is fully applicable for this purpose.
ence between calculated and actual capacity, recorded over
four years varies within a margin of ±1.5% (compare results in Anticipated Research Benefits
Tables 1 and 2).
Final research results are applicable for the following purposes:
1. Pre-selection of a machine with regard to its acquisition; a fu-
ture user should accurately calculate effective reclaiming rate
4 Conclusions of a R&S/R, and make sure whether the machine under con-
sideration matches capacity targets.
The research presented here has been focused primarily on
reclaiming capacity calculation of rail-mounted bucket wheel 2. The follow-up of R&S/R in the reclaiming operation; if large
reclaimers, and stacker/reclaimers (R&SR). The effective re- capacity variations and deviations from planned capacity
claiming capacity represents an actual output of this operation exist, verification ought to be performed to determine possi-
with regard to its influencing factors, such as: ble roots of problems, and solve them. This also helps main-
tain operating cost of the machine low.
• design parameters of the machine,
3. Production scheduling; for operating R&S/R, the effective
Table 1: The change of the effective reclaiming capacity as a function of the depth capacity may be calculated precisely for production schedul-
of the advance L (ThyssenKrupp stacker/reclaimer) ing purposes over an analysed time period. This enables a
maximisation of the machine’s performance.
Li (m) Qeff (m3/h) Qeff(L =15 m)/Qeff(Li) Difference 4. Analysis of potential benefits and assessment of impact of
(%) (%) possible design modifications onto performance of an exist-
5.0 743.14 96.99 % ing machine leading to a choice of the best alternative.
7.5 753.88 98.39 % -1.61 % 5. Development of a new machine (model) by manufacturers of
reclaimers and stacker/reclaimers. Performance of the new
10.0 759.59 99.14 % -0.86 %
model can be calculated precisely for different conditions of
12.5 763.97 99.71 % -0.29 % application in order to optimise its design. This way, the best
alternative may be identified.
15.0 766.19 100.00 % 0.00 %
17.5 767.81 100.21 % 0.21 %
20.0 769.05 100.37 % 0.37 % 5 References
22.5 770.40 100.55 % 0.55 % [1] BERGONZOLI, A. and C. FERRETTI: Calculation Program for
the Analysis of the Performance of Boom-Type Re-
25.0 771.14 100.65 % 0.65 %
claimers; Stacking, Blending & Reclaiming of Bulk Materi-

Tab. 2: Operating parameters of the KRUPP stacker/reclaimer

Item 1997 1998 1999 2000 – Mean Standard

8 months value deviation
(yearly basis)
A Working time (h) 1 450 1 058 1 429 2 223 1 540 490
B Material handled 2 875 862 2 132 834 2 528 075 4 404 372 2 985 286 993 562
(metric tons)
C Material handled 1 106 101 820 321 976 337 1 693 989 1 148 187 382 139
(m3)
D Performance (tm/h) 1 983 2 017 1 769 1 982 1 938 114
(B/A)
E Performance (m3/h) 763 776 680 762 745 44
(C/A)

bulk solids handling • Vol. 24 (2004) No. 3 12

2mm luft lassen

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13 Vol. 24 (2004) No. 3 • bulk solids handling

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