bulk i Volume 5, Number 2, April 1985

solids
t1andUn9

Optimizi:ng Active Stockpile capacity

for TWin Bottom Tunnel Reclaim systems
a. Coldsmith, USA

1. Introduction Determining the cross-section of the stockpile necessitates

Large capacity stockpiles require efficient continuous stack­
ing/ reclaiming systems, and a major parameter dictating the
design of these systems is the required active stockpile
capacity.
Selection of above ground or bottom tunnel reclaim systems
necessitates detailed analyses relating amortization and
operating expenses for the facility and the determination of
the owner's costs when he is unable to meet the com­
mitments for incoming and outgoing shipments. Equating
these factors will yield an optimum storage capacity, as
illustrated in Fig. 1 [1).
establishing the natural angles of repose and reclaim for the
material. Neither can be assumed as fixed values, and it is
recommended that both be established by testwork or survey­
ing existing stockpiles of the same material. Examples of
variables which affect the angles of repose and reclaim
include the surface moisture content, the particle size
distribution and the length of time stockpiled. The cross­
section of the stockpile can also be dictated by the available
land area for the storage and reclaim system.
When both the optimum live storage capacity and the
stockpile geometry have been established, the method
delineated in the following text will provide the maximum
active stockpile capacity for a twin bottom tunnel reclaim
system.

2. Basis for Calculations

Fig. 2 illustrates a cross-section through a stockpile with a
twin tunnel reclaim system, where:
COST
W = base width of the stockpile
H = height of the stockpile
a = natural angle of repose
f3 natural angle of reclaim
e = location of opening(s) for a continuous slot or a
series of mass flow hoppers
Considering one half of the stockpile cross-section, it can be
seen that the location of e must be between the limits
LIVE STORAGE
e > 0 and e < cot {3 (H)
Fig. 1: Optimization of live storage volume
ft follows that deriving an equation for the sum A of the inac­
tive areas between these limits in terms of e, i.e., A = f (e),
When the analyses include a twin bottom tunnel reclaim dA
system, this paper provides a method of calculating the loca­ and solving the equation = O will provide a value for e
de
tion of the tunnels to maximize the active stockpile capacity. when A is minimal.
This method considers the cross-section of the stockpile and
is based, therefore, on areas and not volumes. Volume Referring to Fig. 2:
calculations are of course dependent on the selected method
of material withdraw (continuous slot or a series of mass flow Area (1):
hoppers being typical examples) and the geometry of the
inactive material contained in the end cones. h 1 = tan{J(e)
and
Mr. Brian Goldsmith, Senior Engineer, Project Leader, Draw Engineers, Pitts­ tan2 .B(e)
burgh, PA, USA
Area [/] = --�
2

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Stackjn9, blendjn9 and reclajmjn9 Volume 5, Number 2, April 1985 solllds
handun■

Therefore,
dA
- = tan(J(e) - KW+ 2K(e)
de
H
and when
-
dA
=0
de

KW
e = ----- (2)
(tan(3 + 2K)

Substituting the solution fore in Eq. (1) will then provide the
minimum inactive storage area.
The following example demonstrates the calculation pro­
cedures.

3. Example
Base data
Stockpile width W = 200.00 ft
Angle of repose a = 38 °
INACTIVE
Angle of reclaim (3 = 50 °
AREA

Calculations

(tan(3) (tan a)
• K =
2 (tan(3 + tan a)

0.9311
Fig. 2: Stockpile cross-section 2 (1.9730)

0.2360

KW
• e
(tan(J + 2 K)

Areas [2] and [3]: 0.2360 (200)

(1.1918 + 0.4720)

= 128.3688 ft 1
Since e1 + e2 = (0.5 W - e)
• Total Inactive Area A
(tan (3) (tan a) (0.5----
h i = -'--� W - e)
---
(tan(3 + tan a) tan (J(e)
and = 2 [ : + K (0.5 W - e)2]
(tan(3) (tan a) (0.5 W - e)2
Area [2] + Area [3] = ----------
2 (tan {3 + tan a) 1 · 1918 8 3688) 2
= 2 [ � · + 0.2360 (100 - 28.3688)2]
Therefore, the total inactive area
= 13,380.9930 ft2 I
tan {3 (e)2(tan {3) (tan a) (0.5 W - e)
A=---+----------
2

2 2 (tan(J + tana) • Total C/S Area of Stockpile

Since tan(J and tana will be constants, this equation can be = tan a (0.5 W)2
simplified to
= 0.7813 (100)2
tan2(3(e)2
--- + K (0.5 W - e)2
A
2
(1) = 7,813 ft2

where • Total Active Area

(tan(3) (tan a)
K=
2 (tan(3 + tan a)
J
= 4,432.001 ft2 J
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haft 1•n•

Total Active Area

• Ratio: ----------­
Total CI S Area of Stockpile

4,432.007
7,813

0.5673
= 1 1

4. Commentary
For comparison, a single reclaim system, located at the
center of the same stockpile, yields a ratio of 0.3960, which
can be a significant consideration in the overall analyses.
To illustrate, the following comparison results from a selected
active volume of 10 Mft3 •

System Total Volume Stockpile Leng.th

Mft3 ft
Twin Reclamation 17.63 2,256
Single Reclamation 25.25 3,232
(for a continuous slot opening and not including the stockpile end cones)

To conclude, the data presented in this paper indicate that

in order to evaluate the economic viability of the two reclaim
systems with respect to optimizing the active storage
capacity, it is necessary to analyze not only the equipment
costs, but also the owner's costs for storing the inactive
material. Projected costs for reclamation of this inactive
material by, for example, mobile equipment may also be a
significant factor and should be considered.

References
[1] O yl e r, J. F.: Optimization in Applying Track Mounted
Combination Bucket Wheel Stacker I Reclaimers in Bulk
Material Storage Yards. Bulk Materials Handling V ol. 1,
University of Pittsburgh School of Engineering Publica­
tion Series, Pittsburgh 1971.

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