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MATHEMATICAL MODEL OF STACKING OPERATION OF

STACKER/RECLAIMERS

Conference Paper · October 2017

DOI: 10.7251/BMC170701287S

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 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

DOI: 10.7251/BMC170701287S

MATHEMATICAL MODEL OF STACKING OPERATION OF

STACKER/RECLAIMERS

Lazar STOJANOVIĆ1, Dragan KOMLJENOVIĆ2, Vladimir MALBAŠIĆ1, Mladenko

KNEŽEVIĆ3
1
University of Banja Luka, Faculty of Mining Prijedor, Email: [email protected]
2
Hydro-Quebec’s Research Institute (IREQ), Montreal, Canada Email: [email protected]
3
ArcelorMittal d.o.o.Prijedor Email: [email protected]

ABSTRACT

This paper presents the methodology defining key parameters of the stacking operation of rail-
mounted bucket wheel stacker/reclaimers for raw bulk material handling systems.
Due to gaps in the theory on this topic, the study aims at developing a mathematical model which
characterizes the stacking operation of these machines. It integrates the relevant relationship between
design characteristics of the equipment and the parameters associated with its work environment.
The chevron stacking method has been analysed and a mathematical model of the process is
developed. The model is useful for a blending or homogenizing operation at a stockpile, as well as for
automation of a stockpiling process. Furthermore, the model accurately defines operational parameters
of this process which would enable an improved utilization of the machine and a better operation
management.
Successful validation of the developed model was performed for an operating iron ore mine.

Key words: bucket wheel stacker/reclaimers, bulk material handling systems, stacking operation,
mathematical model

1. INTRODUCTION
Handling and shipment of bulk solid materials plays a vital role in the modern economy. It
involves a steadily increasing volume of raw materials being transported from often remote
mine sites world-wide to treatment facilities in both developed and developing countries. Due
to significant costs of those operations bulk solids handling systems ought to be efficient,
reliable, and highly productive and should enable a good material flow at the least cost. This
requires more efficient reclaiming and stacking machines.
Ground storage is the most economical method of stockpiling solid bulk material, particularly
for a large tonnage. This way, one minimizes the investment and operation/maintenance costs
of structures and auxiliary equipment. This layout is used in a variety of industries. The role

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of large-scale raw bulk materials handling systems using stockyards consists of the following
[[4],[4],[5],[7],[8]]:
 Transfer function: Facilitate a transfer between two or more means of transport;
 Buffer function: Even out capacity fluctuations between supply and destination
facilities;
 Quality function: Even out quality fluctuation of the same raw bulk material on a
stockpile.
The equipment employed to handle raw bulk materials in stockyards is referred to as a
reclaimer (reclaiming operation only), and/or stacker/reclaimer (both functions: stacking and
reclaiming). The most frequently used ones are the rail-mounted boom-type machines, such as
a stacker/reclaimer shown in Figure 1. To simplify, these machines will be referred to as
"R&SR".

Figure 1. Rail-mounted bucket wheel stacker/reclaimer with a slewing boom [[4],[4],[7],[8]]

During the reclaiming operation the bucket of such machines follows a 3D trajectory defined
by a combination of three elementary movements: a) rotation of the bucket around its own
axis; b) slewing of the boom around a vertical axis, and c) travel of the machine on rails
parallel to the pile.
The stacking (stockpiling), as the second operation, can be carried out only by stackers and
stacker/reclaimers. The latter are bucket wheel machines in which the wheel boom conveyor
is reversible. The stockpile conveyor runs in opposite directions for stockpiling and
reclaiming. By this means the belt can convey material from the bucket wheel to the slewing
axis, or alternatively from the slewing axis to the bucket wheel (Figure 2).

Figure 2. Flow of material when using a combined stacker/reclaimer [[4],[7],[8]]

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During a stacking operation performed by a stacker/reclaimer, the material is fed to a belt (as
in the case of a typical stacker), and its bucket wheel does not rotate. The machine travels
alongside the stockyard where bulk material is stockpiled. In general, combined machines are
provided with greater stacking than reclaiming capacity. This way, the time lost in reclaiming
from the stockpile is kept at a minimum. It is of great importance to the subsequent
production process.
In the scientific/technical literature, there are gaps in the theory regarding the stacking
operation of R&S/R. The current paper aims at developing a mathematical model which
characterizes the chevron stacking operation of these machines. It integrates the relevant
relationship between design characteristics of the equipment and the parameters associated
with its work environment. These parameters are quite important for a blending or
homogenizing operation at a stockpile, as well as for automation of a stockpiling process. In
this case, the boom position in stockpiling operation should also be defined. Furthermore, the
paper defines operational parameters of this process which would enable an improved
utilization of the machine and a better operation management.
The case study performed at the Omarska iron ore surface mine demonstrates the applicability
of the methodology.

2. STACKING METHODS

Various methods are available for stacking bulk materials to build up stockpiles of particular
dimensions. In general, three methods of stacking are used in practice for the stockpiling of
bulk solids, such as:
- Chevron stacking (Figure 3a)
- Windrow stacking (Figure 3b)
- Combined stacking (various combinations of the two basic stacking methods)

Figure 3. Stacking methods [[4],[7],[8]]

a) chevron; b) windrow

The chevron stacking is suitable if materials of even lump sizes are handled. Otherwise,
segregation of lumps would occur (large lumps will roll down the side of the pile and collect
at its base). The windrow stacking is preferred to chevron stacking since it provides a better

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blending and homogenization, even for materials of varying lump sizes, can be achieved with
this method. The selection of a particular method depends on the blending and/or efficiency
desired and the type of reclaiming to be adopted.

3. GEOMETRICAL PARAMETERS OF THE CHEVRON STOCKPILING

OPERATION

In order to define operational parameters of a chevron stacking operation, it is necessary to

define the main geometrical parameters of a stockpile cross-section as a function of a stacking
method. The approach is based on previously conducted works in this area [[4],[7],[8]].

3.1 Geometrical parameters of the chevron stacking method – triangular cross-section

of the stockpile

The chevron method stacks material at the center discharge peak. Each subsequent layer
completely covers the previous layer thus forming a chevron cross-section (Figure 3a). During
the chevron stacking operation, each successive layer has a larger volume (Figure 4).

Figure 4. Relationship between main geometrical parameters of the chevron stacking method
– triangular cross-section

To maintain a constant layer thickness, the travel speed of the stacker should be variable; it
should decrease as the layers build the pile. The chevron method represents the most
economical approach to homogenizing material whose lump size is consistent. The single line
discharge at the peak of the pile enables the use of a short luffing boom stacker
(stacker/reclaimer). In the further analysis, the main geometrical parameters of this stacking
method are defined.
- Area of the first stockpiled triangle Ap
According to Figure 4, it may be written:
Ap  0.25  S p2  tan
(1)
The same parameter may be expressed through the stacking output as follows:
Qst
Ap  [m 2 ]
60  vtr (max)
(2)
Where:
Vtr [m/min] – travelling speed of the machine
Qst [m3/h] – stacking output of the machine

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The first layer is built with a maximal travelling speed of the machine.
From equations (1) and (2), one obtains:
Qst  cot 
Sp  [ m]
15  vtr (max)
(3)
- Cross-section areas of subsequent triangles An
They are calculated as follows for nlth triangle (Figure 4):
2
 nl

Anl  0.25   S p  2   ai   tan  [m 2 ]
 i 1  (4)
Where:
 [0] – angle of repose of the material

- Cross-section area increase Anl

The area increase of each stockpiled triangle (layer) represents the difference between the
current triangle and the previous one. It may be written as follows:
 nl 1

Anl  a n   S p  a nl  2   ai   tan  [m 2 ]
 i 1  (5)
The travelling speed in each layer may be determined as follows:

(6)

After defining the width of each stockpiled triangle, their height should also be determined.
This is necessary for a whole determination of parameters for this stacking mode.
- Height of the first stockpiled triangle Hp
According to 0, its value is calculated as follows:
H p  0.5  S p  tan [m]
(7)
- Height of nlth layer
 nl

H nl   0.5  S p   ai   tan  [m]
 i 1  (8)
If the thickness of all layers is constant (a), Hnl is calculated in the following manner:
H nl  0.5  S p  nl  anl  tan [m]
(9)

- Height increase Hnl

According to 0, this value is calculated as the difference between two neighboring layers. At
the same time this increase represents the necessary boom-end hoisting to stack a new layer. It
is calculated as follows:
H nl  H nl  H nl1  anl  tan [m]
(10)

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In the case where, due to technical and operational requirements, it is necessary to stack under
condition Anl  Ap , the value of (anl) is calculated as follows:

anl  0.5   
nl  1  nl  S p [m]
(11)
After determining the geometrical parameters of this stacking mode, it is necessary to define
parameters of the boom-positioning during this operation. For this purpose, Figure 5 is
analyzed.

Figure 5. Parameters of the boom-positioning during chevron stacking method [[4],[7]]

- Height position of the boom-end during the stacking Hsti

During the stacking operation the boom-end shall not touch stockpiled material in order to
ensure an interrupted and safe operation. Therefore, it should be positioned at a safety
distance hst over the stockpile peak. The height of the boom – end is calculated as follows
(Figure 5):
H sti  H i  hst [m]
(12)
This parameter should be calculated for each stockpiled layer.

- Angle of the boom-inclination oi

In a stacking operation, the boom is inclined at a certain angle. It changes with each
stockpiled layer and is calculated in the following manner (Figure 5):
H sti  Yk 0
 oi  arcsin [ ]
Lk (13)
For the first stockpiled triangle, and lower layers, this value is usually negative.
- Distance between the slewing axis of the machine and the stockpile center ast
According to Figure 5, it is a distance which remains constant in the chevron stacking
method. Its value is calculated as follows:
ast  sin  0   X  Lk  cos  0i   d st [m]
(14)

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For a stacking operation, the distance (ast) is usually known. The value to be calculated is the
boom slewing angle 0. After the transformation of equation (14), one obtains:
a st  d st
 0  arcsin [0 ]
X  Lk  cos  0i (15)
The angle 0 changes slightly according to the change in the stockpile height.
By determining these geometrical and design parameters, all operational elements concerning
the chevron stacking method are defined for the triangular cross-section stockpile.

3.2 Geometrical parameters of the chevron stacking method – trapezoidal cross-section

of the stockpile

The previous analysis was carried out for a triangular cross-section of a stockpile. In the case
where the allowed stockpile height is reached, and one has at the disposal an additional
surface remains available, new layers can be added on the existing stockpile side (Figure 6).

Figure 6. Relationship between main geometrical parameters of the chevron stacking method
– trapezoidal cross-section

That stockpiling results in a trapezoidal cross-section shape. Mathematical relationships

obtained above are still valid for this cross-section shape. However, it is necessary to add
some particular clarifications with regard to this working mode.
The following parameters ought to be determined:
- Area of a triangular cross section At
Total area of stockpiled triangle is calculated as follows:
At  0.25  S t2  tan [m 2 ]
(16)

- Extension area increase in a trapezoidal cross-section Antr

Antr  antr  H  0.25  antr  tan  [m 2 ]

(17)
The parameter (a) represents the thickness of additional layers in a trapezoidal cross-section in
the chevron stacking method. Its value depends on operational and design parameters of this
operation. If the value of an area A is previously known, the value of (a) is calculated by
solving formula (17):
 
a  2  H  H 2  A  tan  cot  [m] (18)
The travelling speed of the machine is calculated as per equation (6).

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- Boom slewing angle regarding additional layers in trapezoidal cross-section 0i

For each additional layer in a trapezoidal cross-section, the boom slewing angle also changes.
The same relationships as those shown in Figure 6 remain valid with a slight modification
regarding these additional layers. The slewing angle for each additional layer is calculated as
follows:
i
a st   a j  d st
j 1
 0i  arcsin [0 ]
X  Lk  cos  0i (19)
By determining these geometrical and design parameters, all working elements concerning the
chevron stacking method for a trapezoidal cross-section are defined. As in the previous case,
they may serve as a basis for the planning and automating of this operation.

4. CASE STUDY

The case study has been carried out at the "Omarska" surface iron ore mine. The iron ore bed
"Omarska“ is located in northeast part of Ljubija metal-genetic area in northwest Bosnia. It
consists of two mutually separated Surface pits, SP "Jezero" and SP "Buvac" [ [1],[2],[3]]. The
ore preparation technology is based on gravity – magnetic separation of limonite iron ore with
average quality of 50.50% Fe, 12.50% SiO2, 12.00% H2O. Within process of washing,
crushing, multiple screening, classifying on spiral classifiers and hydro-cyclones as well as
treatment of fine fractions on high intensity electromagnetic separators two commercial
products are prepared:
- Lump ore concentrate -APR, fraction size - 40+10 mm, average quality 54,00% Fe, 7,50
% SiO2,7,00% H2O; angle of repose: 370; material bulk density loose: 1.5 t/m3
- Fine ore concentrate -BPR fraction size - 10+0 mm, average quality 52,00% Fe, 11,00 %
SiO2,12,00% H2O; angle of repose: 370; material bulk density loose: 1.7 t/m3
The ratio Lumps: Fines = 45:55 with mass recovery of approximately 80 % and Fe recovery
of 83 % of the total quantity of around 1.5 million tones yearly [[1],[2],[3]].
The mine uses a stacker/reclaimer "DELATTRE LEVIVIER" which main design and
operational characteristics are presented below:
 Boom length: 28.0 m; Stacking output: 1000 t/h; Maximum travelling speed: 30
m/min;
 Wheel diameter: 6.4 m; Number of buckets: 8; Volume of a bucket: 0.4 m3 (cell-less
buckets);
 Bucket wheel rotation speed: 5.0 rpm; Bucket wheel installed motor power: 75 kW
 Conveyer width: 1200 mm
The stacking is typically performed using chevron method with layers of 15-25 cm in a
normal operation and 8-12 cm in the final shaping phase of the stockpile. The calculated
operational parameter of the stacking operation in 50 layers during a chevron stacking at the
Omarska iron mine are presented in Table 1. Figure 7 graphically depicts the variation of
some key operational parameters (cross-section area increase, boom slewing angle variation
and travelling speed of the machine).

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 Table 1: Parameters of the chevron stacking operation
7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

295
Figure 7. Variations of some operational parameters during the stacking operation
 7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

5. CONCLUSION

The paper presents a detailed mathematical model of the chevron stacking method. It
integrates the applicable relationship between design characteristics of the machine and the
parameters associated with its work environment (geomechanical characteristics of the bulk
raw material and geometrical characteristics of the stockpile).
The case study has been performed at the iron mine Omarska. The obtained results
demonstrate the applicability of the proposed model. It could be used in refining and
optimizing stacking operation at a specific mine site.
The future research work should aim at developing models for other types of stacking
methods (windrow and combined) as well as their impact on the blending/homogenizing
efficiency with regard to the raw material quality and lump size.

REFERENCES

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on Jun 21st 2017)
[2] ArcerolMittal Prijedor, Technical documentation. Prijedor.
[3] Babic, M. 2012. Uzimanje i transport rude sa deponije do utovarnog bunkera Rudnika Omarska (Final
engineering diploma report), Faculty of Mining, Prijedor
[4] Komljenovic, D., Mathematical model of functioning and technical selection of bucket wheel reclaimers and
stacker/reclaimers (PhD Thesis), Laval University, Quebec City, 2002, 179 pp.
[5] Komljenovic, D., Drebenstedt, C., Paraszczak, J., Fytas, K., 2004. Methodology to Calculate the Effective
Reclaiming Capacity of Rail-Mounted Boom-Type Bucket-Wheel Reclaimer and Stacker/Reclaimer, Bulk
Solids Handling, Volume 24, No 3, Clausthal-Zellerfeld, pp. 158-170, Trans Tech Publications.
[6] Komljenovic, D., Nuric, S., Kricak, L., Pantelic, M., 2012. Impact of the Variability of Technological
Parameters on the Effective Reclaiming Capacity of Bucket Wheel Reclaimers, Proceedings of the XX
International Conference MHCL’12, Belgrade
[7] Komljenovic, D., 2017. Selection and Performance of Reclaimers and Stacker-Reclaimers, Lambert
Academic Publishing; ISBN-13: 978-3-330-03074-9, Saarbruecken, Germany. 176 pages
[8] Wõhlbier, R.H. Stacking, Blending, Reclaiming, 1977, Trans Tech Publications, Clausthal, 858 pages

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