FACULTY MECHANICAL, MARITIME AND

MATERIALS ENGINEERING
Delft University of Technology Department Marine and Transport Technology

Mekelweg 2
2628 CD Delft
the Netherlands
Phone +31 (0)15-2782889
Fax +31 (0)15-2781397
www.mtt.tudelft.nl

Specialization: Transport Engineering and Logistics

Report number: 2012.TEL.7724

Title: Bucketwheel stacker/reclaimers:

an analysis of stacking/reclaiming
methods.

Author: K. C. van Horssen

Title (in Dutch) bucketwheel in- en afslag machines: een analyse van de stort- en
afgraafmethoden.

Assignment: literature assignment

Confidential: no

Initiator (university): prof.dr.ir. G. Lodewijks

Initiator (company): ir. D. Mooijman (EMO, Rotterdam)

Supervisor: ir. T. van Vianen

Date: March 27, 2013

This report consists of 35 pages and 8 appendices. It may only be reproduced literally and as a whole. For
commercial purposes only with written authorization of Delft University of Technology. Requests for consult are
only taken into consideration under the condition that the applicant denies all legal rights on liabilities concerning
the contents of the advice.
 FACULTY OF MECHANICAL, MARITIME AND
MATERIALS ENGINEERING
Delft University of Technology Department of Marine and Transport Technology

Mekelweg 2
2628 CD Delft
the Netherlands
Phone +31 (0)15-2782889
Fax +31 (0)15-2781397
www.mtt.tudelft.nl

Student: K. C. van Horssen Assignment type: Literature

Supervisor (TUD): Ir. T. van Vianen Report number: 2012.TEL.7724
Supervisor (Company): Ir. D. Mooijman (EMO)
Specialization: TEL Confidential: no
Creditpoints (EC): 12

Subject: Stacking and reclaiming methods

In dry bulk terminals, materials are temporarily stored in piles

at the stockyard. For each type of material, a separate pile is
formed. Huge machines stack the materials and mostly these
machines are also equipped with a bucket wheel to reclaim the
materials afterwards, see for example Figure 1 which shows
two reclaiming bucket wheel stacker-reclaimers at the EECV
terminal in Rotterdam.
Figure 1: Reclaiming piles
These machines are able to luff the boom, slew the boom and
drive parallel to the stockyard piles. Based on combination of these rotations or movement, there can
be derived several methods to stack or to reclaim materials. This literature assignment focuses on
investigating existing stacking and reclaiming methods, generate alternative methods and evaluate all
methods.

• Investigate and describe existing stacking and reclaiming methods based on literature but also
based on practical experience of the EMO terminal in Rotterdam.
• What are the constraints; like the minimum and maximum stacking height, the maximum area
pressure, width of the stockyard lanes, etc.
• Investigate and calculate other stacking and reclaiming methods and define selection criteria’s
(f.e. energy consumption, reliability, surface occupation, productivity of the machine, etc.) to
evaluate the different methods.
• Evaluate the different stacking and reclaiming methods

It is expected that you conclude with a recommendation for further research opportunities based on
the results of this study.

The report should comply with the guidelines of the section. Details can be found on the website.

The professor,

Prof. dr. ir. G. Lodewijks

Summary
Open storage of bulk solid material is mostly done in stockpiles. The material will be stored with a
stacker, sometimes in combination with wheel loaders. To reclaim the material a reclaimer is used.
Those two machines are often combined into one machine; a stacker/reclaimer. One of the most
common stacker/reclaimer types is the bucket wheel stacker/reclaimer

There are different possible methods to store and reclaim bulk materials with those bucket wheel
stacker/reclaimers.
The five most common methods for stacking are:
• Cone-shell
• Chevron
• Strata
• Windrow
• Advanced block

The four most common methods for reclaiming are:

• Long travel
• Bench reclaim
• Block reclaim
• Pilgrim step

With the last 3 reclaim methods, the reclaimer uses a slewing movement during reclaiming. For the
long travel method the travel movement is the most used movement of the machine.

The selection for a stacking method is normally based on the required blending efficiency. Whereby
the cone-shell has the lowest blending efficiency and windrow the highest.
If the blending efficiency is an important selection criterion for the stacking method, then the selection
of the reclaiming method will be based on the stacking method to avoid abolishing of the blending
efficiency.
When blending is not important, than the capacity of a reclaim method is an important selection
criterion. This capacity depends on the dimension of the stockpile.

At reclaim method the stockpile will be reclaimed in slices. The capacity can be calculated by
determining the dimensions of those slices. This can be done in two manners:

1) The current reclaim capacity (Q [m3/s]) can be determined for a specific position and time with the
cross sectional area of the slice at that point (A [m2]) multiplied with the current velocity (v [m/s]).

C = A*v
2) The reclaim capacity (Q [m3/s]) of each slice can be determined by: determine the volume (V [m3])
of each slice en divide it by the time (∆t [sec]) wherein the slice is reclaimed.

Q =V
∆t
When the reclaim velocity is inversely directly proportional with the cross sectional area of the slice
results this in a constant capacity, which is shown in the figure below for a slewing reclaim method.
Capacity
Q (m3/s)

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90
Slewing angle: θ [o ]

3
Summary (in Dutch)
De openopslag van stortgoederen wordt veelal gedaan in grote hopen. Deze hopen worden gestort
met een opslag machine (stacker), al dan niet ondersteund door laadschoppen. Het afgraven wordt
gedaan met een afgraafmachine (reclaimer). Veelal worden deze twee machines gecombineerd tot
één machine; een stort- afgraaf machine (stacker/reclaimer). Één van de meest toegepaste varianten
hiervan is een graafwiel stacker/reclaimer.

Om met deze graafwiel stacker/reclaimer stortgoederen op te slaan en af te graven zijn verschillende

methodes mogelijk.
De meest bekende opslag methoden zijn:
• Cone-shell
• Chevron
• Strata
• Windrow
• Advanced block

De meest bekende afgraafmethode zijn:

• Long travel
• Bench reclaim
• Block reclaim
• Pilgrim step

Hierbij wordt bij de laatste 3 afgraafmethode gebruik gemaakt van de zwenkbeweging van de graver
en bij ‘long travel’ van de rijdende beweging van de gehele machine.

De keuze voor een stort methode wordt veelal gebaseerd op het meng effect. Waarbij cone-shell het
laagste meng effect heeft en windrow het meest van de bovengenoemde stort methode.
Wanneer bij het storten het mengen van belang was, dan is bij de keuze van de afgraafmethode
meestal de stortmethode de basis van de keuze, om te voorkomen dat het meng effect niet teniet
gedaan wordt.
Als het mengen van product niet belangrijk is, dan is de capaciteit van de methode bepalend voor de
keuze van de afgraafmethode. Waarbij de afmetingen van de hoop zijn van invloed op de capaciteit.

Bij elke afgraafmethode wordt de hoop in sneden afgegraven. Met het bepalen van de afmetingen van
de sneden kan de afgraafcapaciteit bepaald worden. Dit kan op twee manieren:

1) De lokale capaciteit (Q [m3/s]) op een bepaald punt (bepaald hoek) kan bepaald worden door
doorsnede (A [m2]) van snede op dat punt te vermenigvuldigen met de lokale snelheid (v [m/s]).

Q = A*v
2) De capaciteit (Q [m3/s]) per snede kan bepaald worden door: het volume (V [m3])van de snede te
bepalen en te delen door de tijd waarin een snede afgegraven wordt (∆t [sec]).

Q =V
∆t
Wanneer de snelheid van afgraven omgekeerd evenredig is met de doorsnede van de snede resulteert
dit in een constant afgraafdebiet. Zoals in onderstaand figuur afgebeeld voor een afgraafmethode met
zwenkbeweging
Capacity
Q(m3/s)

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

Slewing angle: θ [o ]

4
Contents
Summary ................................................................................................................................................................ 3
Summary (in Dutch) ............................................................................................................................................. 4

1 Introduction ................................................................................................................................................... 6
1.1 Stacking and reclaiming......................................................................................................................... 6
1.2 Machines .................................................................................................................................................. 6
1.3 Goal of the research ............................................................................................................................... 8
1.4 Structure of the report ........................................................................................................................... 8

2 Stacking and Reclaiming methods.............................................................................................................. 9

2.1 Stacking methods ................................................................................................................................... 9
2.1.1 Cone-shell....................................................................................................................................... 9
2.1.2 Chevron (chevcon) ........................................................................................................................ 9
2.1.3 Strata ............................................................................................................................................ 10
2.1.4 Windrow........................................................................................................................................ 10
2.1.5 Advanced block............................................................................................................................ 10
2.2 Reclaiming methods ............................................................................................................................. 11
2.2.1 Long travel ................................................................................................................................... 11
2.2.2 Bench reclaiming ......................................................................................................................... 12
2.2.3 Block reclaiming........................................................................................................................... 12
2.2.4 Pilgrim step .................................................................................................................................. 13
2.3 Relation between a stacking and reclaiming methods. ................................................................... 14

3 Determination of the reclaiming capacity ................................................................................................ 16

3.1 Reclaiming capacity with a slewing reclaiming method (m3/hr) .................................................... 16
3.1.1 Cross-sectional area of a slice ................................................................................................... 16
3.1.2 Slice Volume................................................................................................................................. 21
3.1.3 Slewing Velocity........................................................................................................................... 22
3.1.4 Time .............................................................................................................................................. 23
3.1.5 Capacity ........................................................................................................................................ 23
3.2 Reclaiming capacity using the long-travel reclaiming method)...................................................... 24
3.2.1 Capacity ........................................................................................................................................ 24
3.2.2 Cross-sectional area of a slice ................................................................................................... 24
3.2.3 Slice volume ................................................................................................................................. 24
3.2.4 Travel Velocity ............................................................................................................................. 25
3.2.5 Travel Time .................................................................................................................................. 25
3.3 Example situations................................................................................................................................ 26
3.3.1 Example 1 determination of the capacity ................................................................................ 26
3.3.2 Example 2: determination reclaim efficiency .......................................................................... 29

Conclusions .......................................................................................................................................................... 32
Recommendations and Discussion ................................................................................................................... 33
References ........................................................................................................................................................... 34

Appendix A1 (Detailed calculation cross-sectional area of a reclaiming slice) ........................................... 35

Appendix A2 (Simplification cross-sectional area of a slice)......................................................................... 38
Appendix A3 (Calculation slice thickness ∆r) .................................................................................................. 40
Appendix A4 (Calculation h(θ))......................................................................................................................... 42
Appendix A5 (Calculation slewing angles)....................................................................................................... 43
Appendix A6 (Volume of a slewing slice)......................................................................................................... 49
Appendix A7 (Time calculation for slewing).................................................................................................... 50
Appendix A8 (Volume of a travelling slice)...................................................................................................... 51

5
1 Introduction
A dry bulk terminal is used for the transshipment and storage of several bulk materials like coal, ore,
and agriculture products. It is a buffer between incoming and outgoing bulk materials.
This research analyses the different methods to stack and reclaim materials on an open storage.

1.1 Stacking and reclaiming

Stacking is the process where bulk material is added to a pile. This pile can
be made longitudinal or circular (as shown in Figure 1.1 and Figure 1.2).
This report is mostly based on a longitudinal stockpile, with a certain height
(h), width (w) and length (L). Chapter 2.1 describes how a stockpile is
formed. Figure 1.1 longitudinal

Figure 1.2 circular

Figure 1.3 Stockpile

Reclaiming is the process of removing the bulk material from a pile. This is mostly done by machines
that excavate the stockpile. The bulk material will be loaded in a transport facility like a vessel, train or
truck for example.

Chapter 2.2 explains some reclaim methods.

1.2 Machines

Machines used for the stacking and reclaiming processes are mainly divided in three groups; (i)
machines which only can stack (stacker), (ii) machines which only can reclaim (reclaimer) and (iii)
machines which can perform both functions (stacker/reclaimer).

The motions of the stackers and reclaimers can be classified in three directions: luffing, slewing, and
travelling. (See Figure 1.4)
Luffing is the motion whereby the boom rotates up or down. This is the height referring to a stockpile.
Slewing is the horizontal rotation of the boom around the central axis of the stacker or reclaimer.
Travelling is the motion of the entire stacker or reclaimer on the rails alongside the pile.

Figure 1.4 movements of a bucketwheel stacker/reclaimer

6
Not each stacker or reclaimer can perform all these types of motions. There are three stacker types:
• Fixed stacker (no luffing and slewing. Mostly only travelling)
• Fixed luffing stacker (only luffing is possible and at some machines also travelling)
• Radial luffing stacker (slewing and luffing is possible and at some machines also travelling)
Figure 1.5 shows an example of a fixed stacker and Figure 1.6 an example of a redial luffing stacker.

Figure 1.5 fixed stacker Figure 1.6 Radial luffing stacker

Reclaimers can mainly be classified in three main groups: (i) Scrapers, (ii) Bridge reclaimers and (iii)
bucket wheel reclaimers.

Scrapers reclaim from one side (side scraper) (as shown in Figure 1.8) or both sides (portal scraper)
(as shown in Figure 1.9 ) of a stockpile. The only possible motions are travelling and luffing.
Bridge reclaimers (as shown in Figure 1.10) reclaim the whole cross sectional area at once and
travels perpendicular to the pile during reclaiming. The only motion is travelling.
Bucket wheel reclaimers are reclaiming with a wheel with buckets. (As the name mentioned). All the
three motions are possible. See Figure 1.11 for an example of those machines.

Scrapers

Figure 1.7 an example of a scraper Figure 1.8 Side scraper Figure 1.9 Portal scraper

Bridge reclaimers

Figure 1.10 examples of bridge reclaimers

7
 Bucket wheel reclaimer

Figure 1.11; I example of an stacking stacker/reclaimer ; II operator view during reclaiming; III overview during reclaiming.

1.3 Goal of the research

The goal of this research is:

• Investigate which methods exists to stack and reclaim bulk materials on a stockpile.
• How the stacking and reclaiming methods are related to each other.
• To give an estimation of the capacity of the different reclaim methods. (in m3/h)
The answers on those questions give more information about how to determine which method is most
useful / efficient for a specific situation.

1.4 Structure of the report

This document will describe several stacking and reclaiming methods. The stacking methods are
useful for different stacker types. The reclaim methods are mainly for bucket wheel reclaimers.
Chapter 2.1 describes the different stacking methods and Chapter 2.2 the different reclaim methods.
Chapter 2.3 describes the relations between the stacking and reclaiming methods.
Chapter 3 compares the different reclaim methods based on capacity in m3/h

8
2 Stacking and Reclaiming methods
Stacking and reclaiming of dry bulk materials is briefly material adding to and removing from a
storage pile. For some reason it can be desirable to use a specific method for stacking and reclaiming.
For instance to get a homogeneous bulk material or larger stacking/reclaiming capacities. This chapter
describes different stacking and reclaiming methods and also the relations between those methods.
The discussed stacking methods are applicable for the most common stacker types.

2.1 Stacking methods

Stacking is not only used to store material but can also been used to blend material to get a more
homogeneous material over time. This is mostly the main reason to select a specific method.
Generally a better method for blending is more expensive through time and energy consumption by
more movements.

The five most common methods for stacking are:

• Cone-shell (2.1.1)
• Chevron (2.1.2)
• Strata (2.1.3)
• Windrow (2.1.4)
• Advanced block (2.1.5)

2.1.1 Cone-shell

De cone-shell stacking method is the most

straight forward method to stack material. As
the name suggests, it starts with a cone, up to a
certain height. Then the machine travels a small
distance alongside the stock pile and makes a
new ‘shell’ against the previous. This process is
depicted in Figure 2.1
The advantage of the cone-shell is the low
number of movements of the machine. When
the height of the first cone is reached, the only
movement that remains is the travel-movement
for a new shell. In other words, a fixed stacker Figure 2.1 Cone-shell stacking
can do this method.
This method is often used when blending is not important.

2.1.2 Chevron (chevcon)

A chevron pile is build up in different layers. The

first operation is to make a small stock pile with
one material. The next step is covering this pile
with another material, and so on. In theory a
machine which only can travel can do this
method, like the cone-shell method. To prevent
dust, a stacker which can luff is used. This
makes the drop height smaller. So the stacker
travels alongside the stockpile during stacking,
at the end it will rise the boom and travels back.
If some blending is desirable this is also a
simple way to stack, only the number of travel
movements is more compared to the cone shell. Figure 2.2 Chevron stacking
Another name of chevron method used in a
circular stockpile is chevcon.

9
2.1.3 Strata

The strata method is more or less the same idea

as the chevron. The first step is also to start with
a small stockpile. The next step is to cover one
side instead of both sides by the chevron. Slewing
(rotation) should be possible to realize this
method with the stacking machine.

Figure 2.3 Strata stacking

2.1.4 Windrow

A windrow stockpile is build up in several smaller

stockpiles/layers on top of each other. The stacker
travels along the stockpile. At the end the boom
slews or luffs and after that the machine travels
back. The layers are kept small to get a better
distribution. Therefore a lot of movements are
needed.

Figure 2.4 Windrow stacking

2.1.5 Advanced block

This method is a variation of the cone-shell method. The difference between those methods is that
slewing is also possible during stacking. Instead of only stack in cones one after the other, also cones
next to each other is a possibility.
Figure 2.5 shows the stacking process schematically. At first the machine will be placed such that a
cone can be created at place A. After that the desired height is reached the boom slews to point B to
stack a cone there. This process can be repeated till the maximum slewing angle, or the maximum
stockpile width is reached. (point H in Figure 2.5). Slewing of the stackerboom is the only movement
till this place H. To decrease the drop height it should also be possible to use the luffing movement of
the stacker.
When the desired height of the cone at place H is reached, the stacker travels backwards and
continues the stacking.

Figure 2.5 Movements advanced block operation (by ABB)

10