What Is a Stacker Reclaimer and How Does It Work?

A stacker reclaimer lets you move and store big materials like coal, limestone, or iron ore in large yards. Stacking means you put materials in neat rows. Reclaiming means you take out those materials when you need them. You get help from automatic stacking and reclaiming because it saves time, costs less for workers, and keeps people safer.

• Automation and watching things as they happen make work faster.

• Stackers and reclaimers together use less space and cost less for machines.

Key Takeaways

• Stacker reclaimers move and store big materials like coal and iron ore. They help save time and lower labor costs.

• These machines do two main jobs. They stack materials in neat piles. They also reclaim them when needed. This keeps work moving smoothly.

• Automation in stacker reclaimers makes them safer and more productive. People can control them from far away. This lowers the chance of accidents.

• There are customization choices for stacker reclaimers. This lets them handle different materials. They can fit many industrial needs.

• Stacker reclaimers are used in mining, power generation, and cement production. They are important for handling lots of materials quickly and easily.

Stacker Reclaimer Overview

What Is a Stacker Reclaimer?

A stacker reclaimer helps you move and store lots of materials. You see it at ports, power plants, and mines. Its main job is to make piles and take out materials when needed. This machine does two jobs in one. The stacker makes neat rows of material. The reclaimer takes material out and sends it to the next step.

A stacker reclaimer has many parts that help it work well. Here is a table with the main parts and what they do:

Stacker reclaimers do tough jobs. They can move over 5,000 tons every hour. You use them in big mines and busy ports. These machines move lots of material fast and safely.

Stacker and Reclaimer Systems

Stacker and reclaimer systems help you handle bulk materials easily. They keep your plant working well. You always have enough raw material ready. You can mix different materials to get the blend you want. These systems help keep your output steady by smoothing out changes in material quality.

Here are some important jobs of stacker and reclaimer systems:

• Buffering and distributing: You keep extra raw material so your plant keeps running.

• Composing and blending: You mix materials to get the right blend in your pile.

• Homogenizing: You make sure material properties stay the same for steady processing.

You run stacker and reclaimer systems with a belt conveyor. It moves material from the top of the shed to the stacking area. The stacker drops material to make a pile. When you need material, the rake pulls it to the center. The scraper pushes it into the transfer chute. Another belt conveyor takes it away for processing.

Stacker and reclaimer systems are different from other bulk material machines. They are made for both storing and taking out materials. This makes your work easier and faster. These systems work safely and quickly, so you can do other important things.

Tip: If you want your plant to keep running, stacker and reclaimer systems give you the buffer and blending you need.

Stacking and Reclaiming Process

Stacking Operation

The stacking operation helps you make big piles of material. The stacker moves in the yard and drops material in lines. You can pick different ways to stack, like windrow stacking. This helps spread the material out evenly. It stops the pile from having parts with different quality. If you keep adding material, the pile stays steady and even. You get a good mix of materials, so your plant works well.

Tip: Windrow stacking lets you control how materials mix. This makes the pile safer and more stable.

Reclaiming Operation

When you need material, you use the reclaiming operation. The reclaimer takes material from the pile and moves it to the middle. A bucket wheel or chain bucket system lifts it onto a belt conveyor. The conveyor brings the material to a chute in the center. The chute drops it onto another conveyor for processing.

You can use different machines to make reclaiming easier. Here are some common types:

• Portal scraper reclaimer: Good for long strip yards.

• Gantry chain bucket reclaimer: Moves material from mixed piles to conveyors.

• Bucket wheel reclaimer: Has a spinning wheel with buckets for fast work.

• Cantilever scraper reclaimer: Saves space and is easy to care for.

• Bridge bucket wheel reclaimer: Handles lots of material and mixes it well.

• Silo reclaim systems: Takes material out of silos quickly.

The Silo Reclaim System uses mass flow. All the material moves together to the exit. This stops problems like bridging or rat-holing, so the flow stays smooth.

The tripper lifts the yard conveyor belt and bends it over a guide chute. This lets the material fall onto another conveyor. The bucket wheel picks up material and sends it to the middle. The central chute moves it to the conveyor between the reclaimer rails.

Automation and Safety

Modern stacker reclaimers use smart automation to help you work faster and safer. You can control the machine from far away with fiber optics, radio, or cameras. New PLC controls are better than old relays. They make the machine more reliable and easier to fix. Laser sensors, encoders, and switches help you know where the stacker and reclaimer are.

• PLC controls make your system work better.

• Remote control keeps you safe from danger.

• Sensors give you good data for safe work.

• Operator cab leveling uses gravity or hydraulics for safety and comfort.

You connect your stacker reclaimer to yard conveyors and other machines. You must check if it works with your current conveyors and controls. Standard protocols like OPC UA or Modbus help machines talk to each other. Mobile units can be set up in less than 24 hours.

Note: Automation and safety in stacker reclaimers help you work faster, lower risks, and keep your plant running well.

Stacker-Reclaimer Features & Benefits

Efficiency and Productivity

A stacker reclaimer helps you work faster in your yard. The circular system stores materials by itself. You can use all your storage space, so nothing gets wasted. The machine moves sideways, up and down, and turns around. This helps you stack and reclaim materials quickly. One machine does both jobs, so you save time and energy. Kawasaki’s smart technology lets you change how you work quickly. You need fewer workers because the machine does most jobs. Your work keeps moving without stopping, so you get more done.

Tip: Automated machines help you work faster and safer. This makes your plant better than others.

Reliability and Low Maintenance

You can count on a stacker-reclaimer to work well for years. The moving system keeps the wheels and motor working together. The VVV drive unit puts the motor, brake, and gearbox in one part. This makes the machine run smoothly. Special seals keep iron dust out and parts clean. Rail clamps and cleaners hold the machine steady in storms. Safety switches and stoppers keep things safe. Location encoders help you put the reclaimer in the right spot.

• The design helps the machine work longer with less stopping.

• Safety parts protect workers and the machine.

• You spend less time and money fixing things.

Customization Options

You can pick a stacker reclaimer that fits your job. The machine works with many materials like alumina, clay, ironstone, and coal. You choose the design to match your yard. You pick how much material the machine can handle, like 300 tons per hour or 200 tons per hour. The stacker-reclaimer works in cement, coal, power, metal, and chemical plants. You get the right storage and reclaiming for your plant.

Note: Custom machines help you get the best results for your materials and your plant.

Why Choose Stacker Reclaimer?

Industry Applications

Stacker reclaimers are used in many industries. They help move and store big amounts of material. You see them with coal, minerals, and biomass. These machines work in power plants, ports, and mines. They also help cement, fertilizer, and glass industries. Stacker reclaimers are used for lithium-ion battery recycling. They help with pulp and paper production too.

Stacker reclaimers keep your plant working well. You can store materials safely and get them fast. The closed design keeps materials safe from bad weather. It also helps control dust. This keeps your materials good and stops waste. You save space in your yard, so your work is easier.

Tip: Stacker reclaimers help you move more material with less hard work. This makes your job safer and easier.

Comparison with Other Equipment

Stacker reclaimers are better than other machines for bulk material. They do stacking and reclaiming in one machine. You do not need two separate machines. This gives you better control and higher efficiency.

• Bucket Wheel Stacker-Reclaimer: It works fast and can handle a lot. You need to check and fix it often.

• Bridge-Type Stacker-Reclaimer: It covers big areas and is simple. It does not move as easily as others.

• Portal-Type Stacker-Reclaimer: You can use both sides for more options. It can be harder to fix.

• Semi-Portal-Type Stacker-Reclaimer: It uses space well and works fast. It can wear out quicker.

Stacker reclaimers work all the time and save energy. The bucket wheel moves material quickly and helps you do more. You can change the speed for better control. Old machines only have one speed.

Note: Keep your stacker reclaimer checked and fixed often. Automation helps stop problems like bad oil and machine stops.

Stacker reclaimers help you work faster and safer. You get better results and your plant does not stop for long.

You use stacker reclaimers to move and store big materials like coal and iron ore. The machine puts material in piles and takes it out with a spinning platform. You see these machines at power plants, ports, and mines. Many industries pick stacker reclaimers because they work better, keep people safe, and help the environment. Automation and smart controls make work faster and help meet new rules. As more material is needed, you will see new designs and better technology for handling materials.