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Stacker and reclaimer

systems for cement plants


2

Heavy-duty performance

Key benefits Ideal for both prehomogenisation and


buffer storage of raw materials, FLSmidth
All stacker and reclaimer stacker and reclaimer systems have an
systems are: impressive track record of performance.
FLSmidth has commissioned some of the
- Ideal for both prehomo- largest stackers and reclaimers in the
genisation and buffer cement industry, matching kiln through-
storage puts of up to 12,000-13,000 tpd.
Limestone

- Designed for heavy-duty We offer an extensive selection of


operation stacker and reclaimer systems to meet
precisely your needs.
- Compatible with products
from all types of crushing Selection criteria
installations When planning which stacker and
reclaimer system to use, you will need
to consider various questions before
Coal
selecting type and size:

- Homogenising effect required


- Future uprating of the store
- Open or roofed store
- Mill feed system
- Chemical characteristics of the
materials to be handled

Gypsum
Prehomogenisation
Prehomogenisation is often necessary
in the cement industry, in cases where
the raw material chemical composition
varies greatly.

Prehomogenisation is used primarily


for the main components in cement
production, i.e. limestone and clay.
Shale
With the increasing variation in the
grades of coal used for coal firing
installations, 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. >>

Clay
3

Store types

Homogenising stores
CBS: Circular Blending Systems BS: Longitudinal Bridge Scraper store BE: Bucket Excavator store

CBS type BS type BE type


- High continuous homogenising effect - Suitable for dry to moderately sticky - Only homogenising store suitable
- No end cone problems materials for very sticky materials
- Optimum utilisation of space - Direct feed of free flowing materials - Economical system for large stores
- Fully automatic continuous - Efficient adjustment of long term designed for direct feed of any type
operation (no change of pile) variations in chemical composition of mill
of raw materials - Optimum utilisation of space and
- Store capacity can easily be expanded roofing easy to install

Non-homogenising stores
PS: Portal Scraper store SS: Side Scraper store

PS type SS type
- Suitable for all types of materials - Suitable for sticky materials
including sticky materials - Different types of material can be
- Different types of material can be stacked and reclaimed from
stacked and reclaimed from separate piles
separate piles - Optimum utilisation of building when
- Optimum utilisation of building when using overhead tripper
using overhead tripper - Store capacity can easily be expanded
- Store capacity can easily be expanded
- Low initial cost
4

Methods

Blending effect Stacking methods The Windrow method is preferred in


The blending effect [ H=Sin/Sout] of a Longitudinal stores: The most cases where the reclaimer is only operat-
homogenising stacker/reclaimer system commonly used stacking methods are ing in one part of the pile cross section
is generally determined as the ratio Chevron, Windrow and Cone Shell. at a time or in cases where segregation
between the standard deviation Sin of Basically these methods consist of stack- would make an open pile base
one leading chemical parameter of the ing a large number of layers on top of unacceptable typically in coal stores.
store input and the standard deviation each other in the longitudinal direction
of the same chemical parameter Sout of of the pile. According to the Chevron The Cone Shell method is often used in
the store output. In principle, the stan- method material is deposited by the cases where homogenisation is not nec-
dard deviation is reduced by stacking stacker moving to and fro over the centre essary. The pile is formed by depositing
the material in a large number of layers line of the pile. The Chevron stacking material in a single cone from a fixed
and subsequently reclaiming these layers. method causes segregation of the position. When this conical pile is full,
Theoretically without taking the material with fine particles in the central the depositing of material moves to a
particulate nature of the material into part of the pile and coarse particles on new position and a new cone is formed
account the blending effect is closely the surface and at the bottom of the pile. against the shell of the first one. This
linked to the square root of the number To ensure proper blending a Chevron process continues in the longitudinal
of layers reclaimed simultaneously with pile must therefore be reclaimed from direction of the store until the stockpile
stacking. However, almost every reclaimer the face of the pile, working across the is complete.
operates with some kind of scraper or entire cross section. According to the
bucket chain arrangement, and especially Windrow method material is deposited Circular stores: Continuous Chevron
with coarse particles the actual blending from a number of positions across the stacking is the most commonly used
effect is lower than the theoretical value full width of the pile. The Windrow method. The circular store has a round
because it is limited by the number of method prevents segregation and base with aring-shaped pile being
particles between one pair of scraper ensures more even distribution of fine continuously stacked at one end and
blades or within a bucket. and coarse particles across the pile. reclaimed at the other. Stacking takes

Chevron Windrow Windrow open pile

Continuous Chevron Cone Shell


5

place in a fan shaped arc typically Touchview

120. With each sweeping movement, graphic flatpanel


in operator cabin
Control
corresponding to two layers of
material, the whole sector advances The stackers and reclaimers are controlled
approximately 1/2 ahead. by state-of-the-art PLC-based technology
designed for fully automatic operation.
Reclaiming methods The operation panel is a Touchview Graphic
On/Off mode: The reclaimer is usually Flatpanel (TGF) with finger activated
equipped with constant speed motors. the reclaimer and the mill. This is possi- display. It combines all the necessary start/
The reclaimed material is carried by belt ble in cases where material from one (or stop buttons, lamps and other indication
conveyors driven by constant speed more) store(s) is to be fed to a single instruments in one display that is easy to
motors and discharged into a feed bin mill. In principle, the reclaimer must be overview and operate.
of a relatively large volume. equipped with speed regulated motors
and an integrated belt scale. The trans- The TGF is incorporated in the control desk
Reclaiming capacity is higher than the port and subsequent proportioning of in the air conditioned control cabin on the
mill requirement and the reclaimer the reclaimed material and additional stacker or reclaimer. It connects the stacker
therefore operates in an On/Off mode raw material is effected by speed regu- or reclaimer to the central control system
controlled by maximum/minimum level lated conveyors. via serial or parallel communication.
indicators in the feed bin. On leaving
The PLC make and type may be chosen in
the bin, the material is proportioned Reclaiming capacity will always match
accordance with the individual requirements
and fed to the mill by weigh feeders. the mill requirement and the reclaimer
to facilitate communication with the central
will operate continuously. The reclaimer
control system.
Direct mode: If the materials are diffi- in combination with the transporting
cult to handle, it may be an advantage belt conveyors acts as a weigh feeder The operating status of the stacker or
to avoid the intermediate bin between for the reclaimed material. reclaimer and signal lamps for indication
of working and alarm conditions can be
monitored from the TGF.

Mill feed: On/off mode The stacker and reclaimer control system
with use of weigh feeders is designed to enable complete testing
or direct feed (blue line) before the central control system takes
Crusher over. From the TGF it is possible to test
both single components (valves, motors,
Limestone Clay Sand Iron ore etc.) and the operational functions of the
stacker or reclaimer.
1 2 3 4
There are several parameter and configu-
Storage ration screens which enable operators to
change operating limits and optimise
production. This function ensures that the
machine can be adjusted without having
to use programming equipment.

2 1 Once the central control system is ready to


4 3 function and communication with the TGF
Dosimat is established, all normal operation (start
feeders Raw mill stop, set point changes, etc.) will take
place from the central control system.
6

CBS Circular
Blending System

The Circular Blending system, type CBS, ing parallel to a radius line. For cement
is designed for continuous Chevron production the pile between the bridge
stacking in one ringshaped pile. Stacking scraper and the stacking zone is a buffer
is effected by a fanshaped sprinkling normally representing 3 1/2 to 7 days
action in an arc determined by the type consumption.
of material being processed to ensure
appropriate homogenisation. The material enters the store on a
rubber belt conveyor and is discharged
Reclaiming at the other end of the pile into a centrally positioned inlet hopper
is effected by a bridge reclaimer work- on the stacker jib.

Circular store with raking harrow

Circular store with live harrow Circular store


7

Homogenising store

3 4 6 8
2
5

7 9 11
5
10 12

13
14

1 Incoming belt conveyor 8 Raking harrow The stacker is mounted on the centre
2 Jib 9 Raking car column, which allows rotation in both
3 Conveyor belt, jib 10 Scraper chain directions simultaneously with the
4 Central column 11 Hydraulic chain tension unit vertical movement of the jib. Its height
5 Luffing unit 12 Bogie above the crest of the pile is kept at a
6 Jib counterweight 13 Outlet hopper minimum to reduce dust emission.
7 Operator cabin 14 Outgoing belt conveyor
Reclaiming takes place at the natural
angle of slide. A raking harrow is
mounted on the bridge reclaimer
which rotates anti clockwise around
the central column.

The sweeping movements of the


harrow system cause the material to
slide to the base, where the chain
system then conveys it to the centrally
placed outlet hopper. To loosen sticky
and non-free flowing materials active
live-harrows are available.

The homogenised material leaves the


store by an underground rubber belt
conveyor leading either to a hopper or
direct to, for example, a cement raw mill.
8

BS Longitudinal
Bridge Scraper store

The longitudinal Bridge Scraper store, A capacity of each pile covering 3 to


type BS, operates with two piles. One 7 days requirements is normally recom-
pile is stacked while the other is being mended for cement production.
reclaimed.
9

Homogenising store

2
3

13
11
9 6 4
12
5

14 10 8 7 1

1 Incoming belt conveyor 8 Reclaimer bogie The material entering the store on a rub-
2 Jib 9 Hydraulic tensioning unit ber belt conveyor is discharged from the
3 Conveyor belt on jib 10 Scraper chain jib of the stacker traveling on rails along-
4 Jib counterweight 11 Raking harrow side the store at a preset speed. The
5 Luffing unit 12 Raking car height above the crest of the pile is kept
6 Operator cabin 13 Operator cabin at a minimum to reduce dust emission.
7 Stacker bogie 14 Outgoing belt conveyor
Reclaiming takes place from the face of a
pile at the natural angle of material slide.

The bridge runs on rails on either side of


the stockpile. On the bridge is mounted
a raking harrow system whose sweeping
movements cause the material to slide
to the pile base. To loosen sticky and
non-free flowing materials active
live-harrows are available.

A scraper chain system conveys the


material to the outgoing belt conveyor.

Skew running is automatically compen-


sated for.

The system merely requires an operator


when shunting from one pile to another.
10

BE Bucket
Excavator store

The Bucket Excavator store, type BE


is designed particularly for sticky bulk
materials. The store consists of two or
more longitudinal stockpiles stacked
according to the Windrow method.
While one pile is being stacked, the
other is reclaimed at right angles to the
direction of stacking. A capacity of each
pile corresponding to between 3 1/2
and 7 days production requirements
is normally recommended.

The store normally has two stacking


bridges, one at either end. The
material enters the store on 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 longitudinally
according to the Windrow method.

Stacking bridge
11

Homogenising store

7
8

2 3
1
4
9 10
6

1 First stacking bridge 6 Bucket chain hoist The bucket chain system, supported by
2 Conveyor belt onbridge 7 Reclaiming bridge the scraper arm, is suspended at a fixed
3 Operator cabin 8 Operator cabin angle from the bridge girders. Starting
4 Cable wheel 9 Reclaiming bridge conveyor at the pit-wall a pre-determined cut of
5 Bucket chain 10 Second stacking bridge material is made by moving the reclaimer
in the longitudinal direction into the pile.

Subsequently, material is reclaimed


from the full pile face when the bucket
chain system traverses to the opposite
pit-wall. A new cut in the longitudinal
direction is made and the Bucket chain
System traverses in the opposite direction.

The bucket chain system discharges


the material onto a rubber belt
conveyor on the reclaiming bridge.

This belt conveys the material to an


outgoing rubber belt conveyor running
along the side of the store.

The system only requires an operator


when shunting from one pile to another.
12

PS Longitudinal
Portal Scraper store

The non-homogenising Portal Scraper The material enters the store on a rubber
store, type PS, is normally used in a belt conveyor running along one side of
production line as a bulk material the store. It is discharged onto a stacker
buffer store. jib which is raised and lowered in order
to reduce dust emission. Alternatively,
The store operates with stockpiles stacking can take place by using a
placed in line. While building up one tripper car supported by a frame struc-
pile by Cone Shell or Chevron stacking ture above the pile.
another pile is being reclaimed.
The stacker and the portal scraper travel
on separate rails along the store.
Portal scraper with primary and
secondary arms for covered store

Portal scraper with one arm - outdoor installation Semi portal scraper with one arm
13

Non-homogenising store

7
8
6

4 5
13

3
10
12

1 2 9 11

1 Portal reclaimer bogie 8 Belt conveyor on jib The portal scraper consists of a portal
2 Outgoing belt conveyor 9 Stacker bogie frame with a scraper chain system.
3 Operator cabin 10 Operator cabin The material is reclaimed by the scraper
4 Portal 11 Incoming belt conveyor chain system and in a constant flow
5 Primary scraper chain 12 Hydraulic cylinder transported onto an outgoing rubber
6 Secondary scraper chain 13 Jib counterweight belt conveyor.
7 Jib
The PS1 (Portal Scraper with one arm)
and the SPS1 (Semi Portal Scraper with
one arm) is provided with one scraper
chain only. The PS2 (Portal Scraper
with two arms) has a primary and
secondary scraper chain working on
either side of the pile while the portal
moves to and fro.

The two scraper chain systems are linked


together at a knee joint. The secondary
scraper chain lifts the material to the
crest of the pile, feeding the primary
scraper chain system. The primary
scraper chain system conveys the material
to the outgoing belt conveyor.

The system only requires an operator


when shunting from one pile to another.
14

SS Longitudinal
Side Scraper store

The longitudinal Side Scraper store, pile by Cone Shell or Chevron stacking
type SS, is used in a production line as another pile is reclaimed.
a relatively small bulk material buffer
store. The store operates with stockpiles The material enters the store on a rubber
placed in line. While building up one belt conveyor along one side of the store.
Side scraper store with articulated scraper
arm and tripper car above the pile

Side scraper store with retaining wall


15

Non-homogenising store

12
1 2 9

3 10
4 8

1 Hoist for raising and 7 Belt conveyor on jib It is discharged onto a stacker jib which
lowering chain 8 Stacker bogie is kept close to the pile crest to reduce
2 Operator cabin 9 Operator cabin dust emission. Alternatively, stacking
3 Outgoing belt conveyor 10 Incoming belt conveyor can take place by a tripper car
4 Reclaimer bogie 11 Hydraulic cylinder supported by a frame structure above
5 Scraper chain 12 Jib counterweight the pile.
6 Jib
The stacker and the side scraper travel
on separate rails along the store.The
side scraper reclaims the material by
means of a scraper chain system which
removes one slice at a time from the pile.
The scraper chain fitted with blades or
buckets conveys the materials to the
discharge point above the outgoing
conveyor.

The system only requires an operator


when shunting from one pile to another.
Various stacker systems
supplied by FLSmidth

C 11-13 100-8-ENG V4
Stacking from tripper car above the pile Tripper car

Copyright 2013 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a trademark of FLSmidth A/S. This brochure makes no offers, representations or
warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. www.flsmidth.com

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FLSmidth A/S FLSmidth Inc. FLSmidth Private Limited
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Copenhagen Tel: +1 610-264-6011 (Rajiv Gandhi Salai, Chennai)
Tel: +45 3618 1000 Fax: +1 610-264-6170 Tamil Nadu 603 103
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