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Suitable for raw materials in the cement, coal, pulp and paper, mining and other industries as well as power plants & ports Stacker and reclaimer systems

Fls Stacker

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Page 1: Fls Stacker

■ Suitable for raw materials in the cement,

coal, pulp and paper, mining and other

industries as well as power plants & ports

Stacker and reclaimer systems

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The FLSmidth stackers andreclaimers have a wide rangeof use:

• In the cement industry

• At power plants

• In the paper and pulp industry

• In the fertiliser industry

• In the mining industry

• At desulphurisation plants

• In ports

The stacker and reclaimer systems areused for both prehomogenisation andbuffer storage of raw materials.

Selection criteriaWhen planning which stacker andreclaimer system to use, you will need to consider various questions beforeselecting type and size:

• Homogenising effect required

• Future upgrading of the store

• Open or roofed store

• Mill feed system

• The chemical characteristics of the materials to be handled

Limestone

Coal

Gypsum

Wood chips

Shale

Clay

Introduction

MAIN FEATURES

Suitable for raw materialsin the cement, coal, pulpand paper, mining andother industries as well aspower plants and ports

• Both prehomogeni-sation and buffer storage

• FLSmidth have com-missioned some of the largest stackers and reclaimers in the cement industry, matching kiln throughputs of up to 12-13,000 tpd.

• The stacker and reclaimer systems are designed for heavy duty operation and accept products from all types of crushing installations

• All stacker and reclaimer systems are based on a modular design concept, which makes it possible to supply a large size range using well proven components

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PrehomogenisationPrehomogenisation is often necessary inthe cement industry, in cases where theraw material chemical composition variesgreatly.Prehomogenisation is used primarily forthe main components in cement production, i.e. limestone and clay.With the increasing variation in thegrades of coal used for coal firing installations, there is a growing need forprehomogenisation and storage of coal.Depending on the properties of the coalused, a prehomogenising or buffer storeis used.

Blending effectThe blending effect [ H=Sin/Sout ] of ahomogenising stacker/reclaimer system is generally determined as the ratiobetween the standard deviation Sin ofone leading chemical parameter of thestore input and the standard deviation

Store types

CBS: Circular Blending Systems

CBS type• High continuous homogenising

effect • No end cone problems• Optimum utilisation of space • Fully automatic continuous opera-

tion (no change of pile)

BS: Longitudinal Bridge Scraper store

BS type• Suitable for dry to moderately sticky

materials • Direct feed of free flowing materials • Efficient adjustment of long term

variations in chemical composition of raw materials

• Store capacity can easily be expanded

BE: Bucket Excavator store

BE type• Only homogenising store suitable for

very sticky materials • Economical system for large stores

designed for direct feed of any type of mill

• Optimum utilisation of space and roofing easy to install

PS: Portal Scraper store

SS: Side Scraper store

SS type• Suitable for sticky materials • Different types of material can

be stacked and reclaimed fromseparate piles

• Optimum utilisation of buildingwhen using overhead tripper

• Store capacity can easily be expanded >>>

PS type• Suitable for all types of materi-

als including sticky materials • Different types of material can

be stacked and reclaimed from separate piles

• Optimum utilisation of building when using overhead tripper

• Store capacity can easily be expanded

• Low initial cost

Homogenising stores

Non-homogenising stores

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of the same chemical parameter Sout ofthe store output. In principle, the standard deviation is reduced by stack-ing the material in a large number oflayers and subsequently reclaiming theselayers. Theoretically – without taking theparticulate nature of the material intoaccount – the blending effect is closelylinked to the square root of the numberof layers reclaimed simultaneously withstacking. However, almost everyreclaimer operates with some kind ofscraper or bucket chain arrangement,and especially with coarse particles theactual blending effect is lower than the theoretical value because it is limitedby the number of particles between one pair of scraper blades or within abucket.

Stacking methodsLongitudinal stores: The most commonlyused stacking methods are Chevron,Windrow and Cone Shell. Basically thesemethods consist of stacking a largenumber of layers on top of each other in

cases where homogenisation is not nec-essary. The pile is formed by depositingmaterial in a single cone from a fixedposition. When this conical pile is full,the depositing of material moves to anew position and a new cone is formedagainst the shell of the first one. Thisprocess continues in the longitudinaldirection of the store until the stockpileis complete.Circular stores: Continuous Chevron stacking is the most commonly used method.The circular store has a round base with aring-shaped pile being continuouslystacked at one end and reclaimed at theother. Stacking takes place in a fanshaped arc – typically 120°. With eachsweeping movement, corresponding totwo layers of material, the whole sectoradvances approximately 1/2° ahead.

Reclaiming methodsOn/Off mode: The reclaimer is usuallyequipped with constant speed motors.The reclaimed material is carried by belt

Chevron Windrow Windrow – open pile

Continuous Chevron Cone Shell

>>> the longitudinal direction of the pile.According to the Chevron method ma-terial is deposited by the stacker movingto and fro over the centre line of the pile.The Chevron stacking method causessegregation of the material with fine par-ticles in the central part of the pile andcoarse particles on the surface and at thebottom of the pile. To ensure properblending a Chevron pile must thereforebe reclaimed from the face of the pile,working across the entire cross section.According to the Windrow method mate-rial is deposited from a number of posi-tions across the full width of the pile.The Windrow method prevents segregation and ensures more even distribution of fine and coarse particlesacross the pile. The Windrow method is preferred incases where the reclaimer is only operat-ing in one part of the pile cross sectionat a time or in cases where segregationwould make an open pile base un-acceptable – typically in coal stores.The Cone Shell method is often used in

Methods

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conveyors driven by constant speedmotors and discharged into a feed binof a relatively large volume.

Reclaiming capacity is higher than themill requirement and the reclaimer there-fore operates in an On/Off mode con-trolled by maximum/minimum level indi-cators in the feed bin. On leaving thebin, the material is proportioned and fedto the mill by weigh feeders.

Direct mode: If the materials are diffi-cult to handle, it may be an advantageto avoid the intermediate bin betweenthe reclaimer and the mill. This is possi-ble in cases where material from one (ormore) store(s) is to be fed to a singlemill. In principle, the reclaimer must beequipped with speed regulated motorsand an integrated belt scale. The trans-port and subsequent proportioning ofthe reclaimed material and additionalraw material is effected by speed regu-lated conveyors.

Reclaiming capacity will always matchthe mill requirement and the reclaimer

The stackers and reclaimers are con-trolled by state-of-the-art PLC-basedtechnology designed for fully auto-matic operation.

The operation panel is aTouchview Graphic Flatpanel (TGF)with finger activated display. It com-bines all the necessary start/stop but-tons, lamps and other indicationinstruments in one display that iseasy to overview and operate.

The TGF is incorporated in thecontrol desk in the air conditionedcontrol cabin on the stacker orreclaimer. It connects the stacker orreclaimer to the central control sys-tem via serial or parallel communica-tion.

The PLC make and type may bechosen in accordance with the indi-vidual requirements to facilitate com-munication with the central controlsystem.

The operating status of the stackeror reclaimer and signal lamps forindication of working and alarm con-ditions can be monitored from theTGF.

The stacker and reclaimer controlsystem is designed to enable com-plete testing before the central con-trol system takes over. From the TGFit is possible to test both single com-ponents (valves, motors, etc.) andthe operational functions of thestacker or reclaimer.

There are several parameter andconfiguration screens which enableoperators to change operating limitsand optimise production. This func-tion ensures that the machine can beadjusted without having to use pro-gramming equipment.

Once the central control system isready to function and communica-tion with the TGF is established, allnormal operation (start – stop, setpoint changes, etc.) will take placefrom the central control system.

Mill feed: On/off mode with use of weigh feeders or direct feed (blue line)

Touchview graphic flatpanel in operator cabin.

Control

1 2 3 4

342 1

Storage

Iron oreSandClayLimestone

Crusher

Raw mill

Dosimatfeeders

will operate continuously. The reclaimerin combination with the transportingbelt conveyors acts as a weigh feeder forthe reclaimed material.

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CBS – Circular Blending System

The Circular Blending system, type CBS,is designed for continuous Chevronstacking in one ringshaped pile. Stackingis effected by a fanshaped sprinklingaction in an arc determined by the typeof material being processed to ensureappropriate homogenisation.

Circular store with live harrow

Reclaiming at the other end of the pile iseffected by a bridge reclaimer workingparallel to a radius line. For cement pro-duction the pile between the bridgescraper and the stacking zone is a buffernormally representing 3 1/2 to 7 days'consumption.

The material enters the store on a rub-ber belt conveyor and is discharged intoa centrally positioned inlet hopper onthe stacker jib.

Circular store with raking harrow

Circular store

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Homogenising store

The stacker is mounted on the centrecolumn, which allows rotation in bothdirections simultaneously with the verti-cal movement of the jib. Its height abovethe crest of the pile is kept at a mini-mum to reduce dust emission.

Reclaiming takes place at the naturalangle of slide. A raking harrow ismounted on the bridge reclaimer whichrotates anticlockwise around the cen-

tral column. The sweeping movementsof the harrow system cause

the material to slide tothe base, where the

chain system thenconveys it to thecentrally placedoutlet hopper. Toloosen sticky andnon-free flowing

materials activelive-harrows are

available.The homogenised

material leaves the storeby an underground rubber

belt conveyor leading either to a hopper or direct to, for example, a

cement raw mill.

1 Incoming belt conveyor2 Jib3 Conveyor belt, jib4 Central column5 Luffing unit6 Jib counterweight7 Operator cabin

8 Raking harrow9 Raking car10 Scraper chain11 Hydraulic chain tension unit12 Bogie13 Outlet hopper14 Outgoing belt conveyor

14 13 7 10 9 5 11 12

4 5 6 8

1 2 3

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BS – Longitudinal Bridge Scraper store

The longitudinal Bridge Scraper store,type BS, operates with two piles.

One pile is stacked while the other isbeing reclaimed.

A capacity of each pile covering 3½ to 7days requirements is normally recom-mended for cement production.

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Homogenising store

ted a raking harrow system whosesweeping movements cause the materialto slide to the pile base. To loosen stickyand non-free flowing materials activelive-harrows are available.

A scraper chain system conveys thematerial to the outgoing belt conveyor.

1 Incoming belt conveyor2 Jib3 Conveyor belt on jib

The material entering the store on a rub-ber belt conveyor is discharged from thejib of the stacker traveling on rails along-side the store at a preset speed. Theheight above the crest of the pile is keptat a minimum to reduce dust emission.

Reclaiming takes place from the faceof a pile at the natural angle of materialslide.

The bridge runs on rails on either sideof the stockpile. On the bridge is moun-

4 Jib counterweight5 Luffing unit6 Operator cabin

7 Stacker bogie8 Reclaimer bogie9 Hydraulic tensioning unit

10 Scraper chain11 Raking harrow12 Raking car

13 Operator cabin14 Outgoing belt

conveyor

14 13 12 11 10 9 8 7 6 1 5 4

2 3

Skew running is automatically compen-sated for.

The system merely requires an opera-tor when shunting from one pile toanother.

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BE – Bucket Excavator store

The Bucket Excavator store, type BE isdesigned particularly for sticky bulkmaterials. The store consists of two ormore longitudinal stockpiles stackedaccording to the Windrow method.While one pile is being stacked, theother is reclaimed at right angles to thedirection of stacking. A capacity of eachpile corresponding to between 3 1/2 and7 days' production requirements is nor-mally recommended.

The store normally has two stackingbridges, one at either end. The materialenters the store on a rubber belt convey-or running along one side. It is dis-charged onto the upper conveyor on thestacking bridge in operation and pro-ceeds to the lower reversible shuttleconveyor which stacks the material lon-gitudinally according to the Windrowmethod.

The bucket chain system, supportedby the scraper arm, is suspended at afixed angle from the bridge girders.Starting at the pit-wall a pre-determined

Stacking bridge

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cut of material is made by moving thereclaimer in the longitudinal directioninto the pile.

Subsequently, material is reclaimedfrom the full pile face when the bucketchain system traverses to the oppositepit-wall. A new cut in the longitudinaldirection is made and the bucket chain

1 First stacking bridge2 Conveyor belt on

bridge3 Operator cabin4 Cable wheel5 Bucket chain 6 Bucket chain hoist7 Reclaiming bridge8 Operator cabin9 Reclaiming bridge

conveyor10 Second stacking

bridge

1 2 3 4 5 6 7 8 9 10

system traverses in the opposite direc-tion.

The bucket chain system dischargesthe material onto a rubber belt conveyoron the reclaiming bridge.

This belt conveys the material to anoutgoing rubber belt conveyor runningalong the side of the store.

The system only requires an operatorwhen shunting from one pile to another.

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PS – Longitudinal Portal Scraper store

The non-homogenising Portal Scraper store, type PS, isnormally used in a production line as a bulk materialbuffer store.The store operates with stockpiles placed in line. Whilebuilding up one pile by Cone Shell stacking another pileis being reclaimed. The material enters the store on a rubber belt conveyorrunning along one side of the store. It is dischargedonto a stacker jib which is raised and lowered in orderto reduce dust emission. Alternatively, stacking can takeplace by using a tripper car supported by a frame struc-ture above the pile.

The stacker and the portal scraper travel on separaterails along the store.The portal scraper consists of a portal frame with ascraper chain system. The material is reclaimed by thescraper chain system and in a constant flow transport-ed onto an outgoing rubber belt conveyor. The PS1 (Portal Scraper with one arm) and the SPS1(Semi Portal Scraper with one arm) is provided with onescraper chain only. The PS2 (Portal Scraper with twoarms) has a primary and secondary scraper chain work-ing on either side of the pile while the portal moves toand fro.

Portal scraper with one arm - outdoor installation Semi portal scraper with one arm

Portal scraper with primary and secondary arms for covered store

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Non-homogenising store

The two scraper chain systems are linked together at aknee joint. The secondary scraper chain lifts the materi-al to the crest of the pile, feeding the primary scraperchain system. The primary scraper chain system conveysthe material to the outgoing belt conveyor.The system only requires an operator when shuntingfrom one pile to another.

1 Portal reclaimer bogie2 Outgoing belt conveyor3 Operator cabin4 Portal5 Primary scraper chain6 Secondary scraper chain7 Jib8 Belt conveyor on jib9 Stacker bogie10 Operator cabin11 Incoming belt conveyor12 Hydraulic cylinder13 Jib counterweight

1 2 3 4 5 6 7 8 9 10 11 12 13

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SS – Longitudinal Side Scraper store

The longitudinal Side Scraper store, typeSS, is used in a production line as a rela-tively small bulk material buffer store.The store operates with stockpiles placedin line. While building up one pile by

It is discharged onto a stacker jib whichis kept close to the pile crest to reducedust emission. Alternatively, stacking cantake place by a tripper car supported bya frame structure above the pile.

cone shell stacking another pile isreclaimed.The material enters the store on a rub-ber belt conveyor along one side of thestore.

Side scraper store with articulated scraper arm and tripper car above the pile

Side scraper store with retaining wall

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Non-homogenising store

1 Hoist for raising and lowering chain2 Operator cabin3 Outgoing belt conveyor4 Reclaimer bogie5 Scraper chain6 Jib

The stacker and the side scraper travelon separate rails along the store.The side scraper reclaims the material bymeans of a scraper chain system which

removes one layer at a time from thepile. The scraper chain fitted with bladesconveys the materials to the dischargepoint above the outgoing conveyor.

7 Belt conveyor on jib8 Stacker bogie9 Operator cabin10 Incoming belt conveyor11 Hydraulic cylinder12 Jib counterweight

1 2 3 4 5 6 7 8 9 10 11 12

The system only requires an operatorwhen shunting from one pile to another.

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Various stacker systems supplied by FLSmidth

Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for generalreference only and may change any time. Please contact us for specific information or data that may relate to your interests.

www.flsmidth.com

For a full list of FLSmidth Group Companies, visit www.flsmidth.com

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DENMARKFLSmidth A/SVigerslev Allé 77 DK-2500 ValbyCopenhagenTel: +45 36 18 10 00Fax: +45 36 30 18 20E-mail: [email protected]

USAFLSmidth Inc.2040 Avenue CBethlehem, PA 18017-2188Tel: +1 610-264-6011Tel: +1 800-523-9482Fax: +1 610-264-6170E-mail: [email protected]

INDIAFLSmidth Private LimitedFLSmidth House 34, Egatoor, Kelambakkam (Rajiv Gandhi Salai – Chennai)Tamil Nadu – 603 103 Tel: +91-44-4748 1000Fax:+91-44-2747 0301E-mail: [email protected]

Tripper car

Stacking from tripper car above the pile

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