Stacker and reclaimer systems

Handling cement raw materials, coal, pulp and paper, minerals

Serving both prehomogenisation and buffer storage

Alternative systems supplied by FLS

Data in this brochure is intended for preliminary project planning only. Manufacturer reserves the right to modify equipment details and/or specifications without notice.

DENMARK F.L.Smidth & Co. A/S MEXICO F.L.Smidth-Fuller Mexico, S.A. de C.V. Fax: +90 - 212-249-16-60Vigerslev Allé 77, DK-2500 Valby, Copenhagen Tel: +52 - 836-33150 UNITED KINGDOM F.L.Smidth-Fuller Ltd.Tel: +45 - 36 18 10 00 Fax: +52 - 836-33421 Tel: +44 - 181-686-2422Fax: +45 - 36 30 18 20 PAKISTAN FLS Pakistan (Pvt.) Ltd. Fax: +44 - 181-681-7229Internet: http://www.flsmidth.com Tel: +92 - 51 29 31 95

Fax: +92 - 51 29 31 96 Licensees/joint venturesUSA Fuller Company PHILIPPINES F.L.Smidth & Co. A/S INDIA Larsen & Toubro Ltd. (Licensee)2040 Avenue C, Bethlehem, Tel: + 63 - 2-824-7676 Cement Machinery Division, Powai WorksPa 18017-2188 Fax: +63 - 2-824-7676 Tel: +91 - 22-8581401Tel: +1 - 610-264-6011 P. R. OF CHINA F.L.Smidth & Co. A/S Fax: +91 - 22-8581126Fax: +1 - 610-264-6170 Tel: 86 - 106 4677070

Fax: 86 - 106 4677071 A member of the F.L.SMIDTH-FULLER F.L.Smidth subsidiaries: SOUTH AFRICA Fuller-F.L.Smidth (PTY) Ltd. ENGINEERING GROUPBRAZIL F.L.Smidth Comércio e indústria Ltda. F.L.Smidth & Co. (SA) (PTY) Ltd.Tel: +55 - 11-532-8500 Tel: +27 - 11-470-9700Fax: +55 - 11-533-9612 Fax: +27 - 11-475-7665FRANCE F.L.Smidth-Fuller S.A. SPAIN F.L.Smidth & Cia Española, S.A.Tel: +33 - 1-4944-6800 Tel: +34 - 91-634-90-00Fax: +33 - 1-4308-5099, +33 - 1-4308-5188 Fax: +34 - 91-636-11-50GERMANY F.L.Smidth-Fuller GmbH THAILANDTel: +49 - 211-591-038 c/o Advance Euro Co., Ltd.Fax: +49 - 211-593-223 Tel: +66 - 2-714-1800INDONESIA FLS Indonesia-Fuller Indonesia Fax: +66 - 2-714-1807Tel: +62 - 21-251-2738 / 2739 TURKEY F.L.Smidth & Co. A/S Liaison OfficeFax: +62 - 21-251-2740 Tel: +90 - 212-249-13-95

Tripper car

Circular portal scraper store Longitudinal scraper storewith transfer car arrangement

Circular side scraper store

Main features

Both prehomogenisation and buffer storage

Available for

FLS has commissioned some of the largest stackers and reclaimers in the cement industry, matching kiln throughputs of up to10-11,000 tpd.

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

All FLS 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.

raw materials in the cement, coal, pulp and paper, mining industries etc.

Selection criteria ! homogenising effect required When planning which stacker

! future uprating of the store and reclaimer system to use, ! open or roofed store you will need to consider ! mill feed systemvarious questions before ! the chemical characteristics selecting type and size:

of the materials to be handled

+ In the cement industry+ At power plants FLS stacker and reclaimer + In the paper and pulp systems are used for both

industry prehomogenisation and + In the fertiliser industry buffer storage of raw + In the mining industry materials.+ At desulphurisation plants

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Mat

eria

ls H

and

ling

ClayWoodchips

Gypsum

Coal

Shale

Limestone

FLS stackers and reclaimers have a wide range of use:

Non-homogenising store

The stacker and the side removes one slice at a time The system merely requires an scraper travel on separate from the pile. The scraper operator when shunting from rails along the store. chain fitted with blades one pile to another.

The side scraper reclaims conveys the materials to the the material by means of a discharge point above the scraper chain system which outgoing conveyor.

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1 2 3 4 5 6 7 9 108 11 12

1 Hoist for raising and lowering chain 6 Jib 11 Hydraulic cyl inder2 Operator cabin 7 Belt conveyor on jib 12 Counterweight for jib3 Outgoing belt conveyor 8 Bogie for stacker4 Bogie for reclaimer 9 Operator cabin5 Scraper chain 10 Incoming belt conveyor

Prehomogenisation is often necessary in the cement indu-stry, in cases where the raw material chemical composi-tion varies greatly.Prehomogenising is used primarily for the main compo-nents in cement production, i.e. limestone and clay.

With the increasing varia-tion in the grades of coal used for coal firing installa-tions, there is a growing need for prehomogenisation and storage of coal. Depending on the properties of the coal used, a prehomogenising or buffer store is used.

Blending effectThe blending effect [ H=S /S ] of a homogeni-in out

sing stacker/reclaimer system is generally determined as the ratio between the standard deviation S of one leading in

chemical parameter of the store input and the standard deviation of the same chemi-cal parameter S of the store out

output. In principle, the stan-dard deviation is reduced by stacking the material in a large number of layers and subsequently reclaiming these layers. Theoretically - without taking the particulate nature of the material into account - the blending effect is closely linked to the square root of the number of layers reclai-med simultaneous with stac-king. However, almost every reclaimer operates with some kind of scraper or bucket chain arrangement and espe-cially with coarse particles the actual blending effect is lower than the theoretical value because it is

Main featuresCHO type:· High continuous

homogenising effect · No end cone problems

(except during initial startup) · Optimum utilisation of space · Fully automatic operation

(no change of pile)

LHO 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

BCE 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 type:· Suitable for sticky materials · Different types of material

can be stacked and reclaim-ed from separate piles

· Optimum utilisation of building when using tripper

· Store capacity can easily be expanded

· Low initial cost

SS type:· Suitable for sticky materials · Different types of material

can be stacked and reclaim-ed from separate piles

· Optimum utilisation of building when using tripper

· Store capacity can easily be expanded

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Homogenising stores

Non-homogenising stores

Prehomogenisation

SS: Longitudinal Side Scraper store

While building up one pile by stacker jib which is kept close The FLS longitudinal Side cone shell stacking another to the pile crest to reduce Scraper store, type SS, is used pile is reclaimed. dust emission. Alternatively, in a production line as a The material enters the stacking can take place by a relatively small bulk material store on a rubber belt tripper car supported by a buffer store. conveyor along one side of frame structure above the

The store operates with the store. pile.stockpiles placed in line. It is discharged onto a

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Description

CHO: Circular bridge scraperstore

PS: Portal Scraper store

BCE: Bucket Chain Excavator store

LHO: Longitudinal bridgescraper store

SS: Side Scraper store

limited by the number of Circular stores: Continuous particles between one pair of Chevron stacking is the most scraper blades or within a commonly used method.bucket.

Stacking methodsLongitudinal stores: The most commonly used stacking methods are Chevron,

The Windrow method is Windrow and Cone Shell. preferred in cases where the Basically these methods reclaimer is only operating in consist of stacking a large one part of the pile cross number of layers on top of section at a time or in cases each other in the longitudinal

direction of the pile.According to the Chevron

method material is deposited by the stacker moving to and

The circular store has a round fro over the centre line of the base with one pile being pile. continuously stacked at one end and reclaimed at the other. Stacking takes place in

where segregation would a fan shaped arc - typically omake an open pile base 120 . With each sweeping

unacceptable - typically in movement corresponding to coal stores. two layer of material, the

The Cone Shell method is whole sector moves ooften used in cases where approximately ½ ahead.

homogenisation is not The Chevron stacking method necessary. The pile is formed causes segregation of the Reclaiming methodsby depositing material in a material with fine particles in On/Off mode: The reclaimer is single cone from a fixed the central part of the pile usually equipped with position. When this conical and coarse particles on the constant speed motors. The pile is full, the depositing of surface and at the bottom of reclaimed material is carried material moves to a new the pile. To ensure proper by belt conveyors driven by position and a new coneblending a Chevron pile must constant speed motors and is formed against the shell of therefore be reclaimed from discharged into a feed bin of the first one. This process the end of the pile, working a relatively large volume.continues in the longitudinal across the entire cross Reclaiming capacity is direction of the store until the section. higher than the mill require-stockpile is complete.According to the Windrow ment and the reclaimer there-

method material is deposited from a number of positions across the full width of the pile.

The Windrow method prevents segregation and ensures more even distribution of fine and coarse particles across the pile.

Chevron

Windrow - open pile

Windrow

Cone Shell

Continuous Chevron

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Non-homogenising store

The two scraper chain feeding the primary scraper The system merely requires an systems are linked together at chain system. The primary operator when shunting from a knee joint. The secondary scraper chain system conveys one pile to another.scraper chain lifts the material the material to the outgoing to the crest of the pile belt conveyor.

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731 8 10 1311 1294 5 62

1 Bogie for portal reclaimer 6 Secondary scraper chain 11 Incoming belt conveyor2 Outgoing belt conveyor 7 Jib 12 Hydraulic cylinder3 Operator cabin 8 Belt conveyor on jib 13 Jib counterweight4 Portal 9 Bogie for stacker5 Primary scraper chain 10 Operator cabin

can be monitored from the TGF.

The TGF offers a wide range of options. The FLS stacker and reclaimer control system is designed to enable complete testing before the central control system takes over. From the TGF it is possible to test both single components (valves, motors, etc.) and the opera-tional functions of the stacker or reclaimer.

There are several para-meter and configuration screens which enable opera-tors to change operating limits and optimise produc-

fore operates in an On/Off tion. This function ensures mode controlled by maxi- FLS stackers and reclaimers that the machine can be adju-mum/ minimum level indica- are controlled by state-of-the- sted without having to use tors in the feed bin. Having art PLC-based technology programming equipment. left the bin, the material is designed for fully automatic Once the central control proportioned and fed to the operation. system is ready to function mill by weigh feeders. The operation panel is a and communication with the

Touchview Graphic Flatpanel TGF is established, all normal Direct mode: If the materials (TGF) with finger activated operation (start - stop, set are difficult to handle, it may display. It combines all the point changes etc.) will take be an advantage to avoid the necessary start/stop buttons, place from the central control intermediate bin between the lamps and other indication system.reclaimer and the mill. This is instruments in one display possible in cases where that is easy to overview and material from one (or more) operate.store(s) is to be fed to a single The TGF is incorporated in mill. In principle, the reclaimer the control desk in the air must be equipped with speed conditioned control cabin on regulated motors and an inte- the stacker or reclaimer. It grated belt scale. The trans- connects the stacker or port and subsequent propor- reclaimer to the central tioning of the reclaimed control system via serial or material and additional raw parallel communication. material is effected by speed The PLC make and type regulated conveyors. may be chosen in accordance

Reclaiming capacity will with the customer's always match the mill require- preferences to facilitate ment and the reclaimer will communication with the operate continuously. The central control system.reclaimer in combination with The operation status of the the transporting belt con- stacker or reclaimer and veyors acts as a weigh feeder signal lamps for indication of for the reclaimed material. working and alarm conditions

Limestone Clay Sand Iron ore

1 2 3 4

3

Storage

Crusher

Raw mill

DosimatFeeders

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

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5

Touchview graphic flatpanel

Control

PS: Longitudinal Portal Scraper store

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which is raised and lowered in onto an outgoing rubber belt The FLS Non-homogenising order to reduce dust conveyor. Portal scraper store, type PS, emission. Alternatively, The PS1 (Portal Scraper is normally used in a stacking can take place by with one arm) and the SPS1 production line as a bulk using a tripper car supported (Semi Portal Scraper with one material buffer store. by a frame structure above arm) is provided with one The store operates with the pile. scraper chain only. The PS2 stockpiles placed in line. The stacker and the portal (Portal Scraper with 2 arms) While building up one pile by scraper travel on separate has a primary and secondary Cone Shell stacking another rails along the store. scraper chain working on pile is being reclaimed. The portal scraper consists either side of the pile while

The material enters the of a portal frame with a the portal moves to and fro. store on a rubber belt scraper chain system. The conveyor running along one material is reclaimed by the side of the store. It is scraper chain system and in a discharged onto a stacker jib constant flow transported

Portal scraper with 1 arm

Portal scraper with 2 arms

Semi portal scraper

Description

Homogenising store

The stacker is mounted on minimum to reduce dust the centre column, which emission.allows rotation in both directions simultaneously with the vertical movement of the jib. Its height above the crest of the pile is kept at a

to an outgoing rubber belt conveyor running along the

The bucket chain system side of the store.discharges the material onto The system merely requires an a rubber belt conveyor on the operator when shunting from reclaiming bridge. one pile to another.This belt conveys the material

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CHO: Circular bridge scraper store

material being processed to is a buffer normally The FLS Circular bridge ensure appropriate homo- representing 3½ to 7 days' scraper store, type CHO, is genisation. consumption. designed for continuous Reclaiming at the other end The material enters the Chevron stacking in one of the pile is effected by a store on a rubber belt ringshaped pile. Stacking is bridge reclaimer working conveyor and is discharged effected by a fanshaped parallel to a radius line. The into a centrally positioned sprinkling action in an arc pile between the bridge inlet hopper on the stacker determined by the type of scraper and the stacking zone jib.

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Covered circular store phot

o: G

eom

etric

a

Description

1 First stacking bridge 6 Hoist for scraper chain2 Conveyor belt on bridge 7 Reclaiming bridge3 Operator cabin 8 Operator cabin4 Wheel for cables 9 Reclaiming bridge conveyor5 Scraper 10 Second stacking bridge

1 2 3 5 6 9 10874

LHO: Longitudinal bridge scraper store Homogenising store

The material entering the natural angle of material available.store on a rubber belt slide. A scraper chain system conveyor is discharged from The bridge runs on rails on then conveys the material to the jib of the stacker traveling either side of the stockpile. the outgoing belt conveyor. on rails alongside the store at On the bridge is mounted a Skew running is auto-a preset speed. The height raking harrow system whose matically compensated for. above the crest of the pile is sweeping movements cause The system merely requires kept at a minimum to reduce the material to slide to the an operator when shunting dust emission. pile base. To loosen sticky and from one pile to another.

Reclaiming takes place non-free flowing materials from the end of a pile at the active live-harrows are

One pile is stacked while Each pile capacity covering The FLS Longitudinal bridge reclaiming takes place from 3½ to 7 days' requirements is scraper store, type LHO, is the other pile. normally recommended.operating with two piles.

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Stacker

1 Incoming belt conveyor 6 Operator cabin 11 Raking harrow2 Jib 7 Bogie for stacker 12 Raking car3 Conveyor belt on jib 8 Bogie for reclaimer 13 Operator cabin4 Jib counterweight 9 Hydraulic tensioning unit 14 Outgoing belt conveyor5 Luffing unit 10 Scraper chain

17814 10 91113 12 6 45

2 3

Description

BCE: Bucket Chain Excavator store

longitudinally according to Subsequently, material is The FLS Bucket Chain the Windrow method. reclaimed from the full pile Excavator store, type BCE is The Bucket Chain System, face when the Scraper Chain designed particularly for supported by the scraper arm, System traverses to the sticky bulk materials. The is suspended at a fixed angle opposite pit-wall. A new cut store consists of two or more from the bridge girders. in the longitudinal direction is longitudinal stockpiles Starting at the pit-wall a pre- made and the Scraper Chain stacked according to the determined cut of material is System traverses in the Windrow method. While one made by moving the opposite direction.pile is being stacked, the reclaimer in the longitudinal other is reclaimed at right direction into the pile. angles to the direction of stacking. Each pile capacity corresponding to between 3½ and 7 days' production requirements is normally recommended.

The store normally has two stacking bridges, one at either end. The material enters the store by a rubber belt conveyor running along one side. It is discharged onto the upper conveyor on the stacking bridge in operation and proceeds to the lower reversible shuttle conveyor which stacks the material

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Stacking bridge

Description

Homogenising store

Reclaiming takes place at the of the harrow system cause active live-harrows are natural angle of slide. A the material to slide to the available.raking harrow is mounted on base, where the chain system The homogenised material the bridge reclaimer which then conveys it to the leaves the store by an under-rotates anticlockwise around centrally placed outlet ground rubber belt conveyor the central column. hopper. To loosen sticky and leading either to a hopper or

The sweeping movements non-free flowing materials direct to the raw mill.

1 Incoming belt conveyor 6 Jib counterweight 11 Hydraulic chain tension unit2 Jib 7 Operator cabin 12 Bogie3 Conveyor belt, jib 8 Raking harrow 13 Outlet hopper4 Central column 9 Raking car 14 Outgoing belt conveyor5 Luffing unit 10 Scraper chain

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