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Stacker – Effective and Reliable Stacking Bulk Materials in Stockyard Operation

Key Benefits

TechSolutions stacker is designed with robustness, fast operation, and high throughputs, and cost effectiveness, reliability, and eco-friendliness.

  • Higher Cost Performance
    TechSolutions offers more cost-effective design and supply solutions, reduce project cost (CAPEX).
  • Lower Operation Cost
    TechSolutions stackers have higher production efficiency, safety and reliability performance achieving the lower cost per tonne (OPEX).
  • Reduced Risks
    Optional turnkey delivery and modularization fabrication, pre-assembly solution, minimizes on-site erection, installation and construction work, plug-and-play is available, reduces project risks.
  • Eco-friendliness and Safely
    Today’s environmental and safety requirements are increasingly strict, TechSolutions stackers are equipped with all the necessary precautionary equipment and systems to minimize the impact of noise, dust emissions on operators and the surroundings.
  • Fully Automatic and Unmanned Operation System
    TechSolutions offers optional fully automatic and unmanned operation systems, minimized manual operation and maintenance costs.

TechSolutions Customized Stacker Solutions

Overview

TechSolutions stackers effectively stockpile bulk materials in an efficient and orderly manner. rail-mounted or crawlers, stationary or traveling, stackers can be supplied in fixed, luffable or luffable-and-slewable boom designs, with capacities from up to 21,500 tons per hour. The design of stackers depends on factors such as the stacking method (Chevron stacking, Windrow stacking and Cone Shell stacking) and size of the stockpile, the type of material, the required throughput and the demand for mobility. Tripper cars or tripper systems for transferring material from the yard conveyor to the stacker are considered part of the stacker.

Stackers Types & Products Range

TechSolutions can design, supply, install & commission different types of stackers according to client’s technical requirements, whether the stackers are stationary or traveling, rail-mounted or rubber-tyred, fixed boom, luffable boom or slewable & luffable boom stackers.

  • Luffable and Slewable Stackers
    Luffable and slewable stacker is able to luff and slew the boom and designed to service stockpiles on both sides of the rails. The initial cost of this stacker can be quickly recovered by economies gained from their flexible mode of operation, as well as their ability to effect good layering and excellent blending. Luffable and slewable stacker boom length can range from 20 to over 65 meters, and the exact configuration as well as the operational features will depend on the application. The following two configuration can be provided:
    – Pylon type luffable and slewable stacker
    Used for standard heavy-duty applications.
    – Cantilevered type luffable and slewable stacker
    Simple design and used for light-duty applications with low migration of center of gravity.
  • Luffable Stackers
    Luffable-only stacker is used for applications where the stockpile is required to be stacked from one side only, with little or no demand for blending. Luffable-only stacker don’t have a slewing mechanism, which makes them an economical option in the right applications. Boom length can range from 20 to over 60 meters, the exact configuration and the operational features will depend on the application. The following two configuration can be provided:
    – Twin boom luffable-only stacker
    – Single boom luffable-only stacker
  • Radial Type Stacker
    TechSolutions radial stacker conveyor belt widths from 650mm to 2400mm, lengths from 20m to 75m for a typical capacity range of 200 to 5000 tons per hour. Adopting of the stacker conveyor allows stockpiles to be more strategically placed, more quickly processed and, when there is a series of stackers, it can work faster and more efficiently than fixed conveyors.
  • Movable Type Stacker
    TechSolutions movable stackers belt widths from 650mm to 1800mm, lengths up to 40m. The movable stacer has a typical capacity range of 300 to 3600 tons per hour. A combination of movable feeder and movable stacker can be used to load barges or ships.

Main Components of Stacker

Stacker consists of several key components that work together to facilitate the stacking and organization of materials in stockyards. The main components of a stacker include:

The superstructure is the upper part of the stacker, housing crucial components such as the boom, control systems, and other operational elements.

The boom is an extendable arm that carries the material-handling equipment. It can be raised, lowered, and maneuvered to precisely stack materials in desired configurations.

The luffing system allows the boom to move vertically, enabling the stacker to adjust the height of the material being deposited. This is especially important for creating stockpiles of varying heights.

The slewing mechanism allows the boom to rotate horizontally, enabling the stacker to cover a larger area and stack materials in different stockpile configurations.

Long travel bogies are the undercarriage or wheel systems that allow the stacker to move along rails or tracks within the stockyard. These provide the necessary mobility for the stacker.

The substructure is the structural support beneath the superstructure, including the slew deck, portal, slew bearing and balance beam. It transfers loads from the superstructure to the travel system efficiently.

In some stacker configurations, a tripper car is employed to distribute material along the length of a conveyor, allowing for precise and controlled stacking.

The cable reel houses and manages the cables that provide power and control signals to the moving parts of the stacker. It ensures a reliable and organized cable system.

The E-house is a containerized housing that accommodates the electrical components and control systems of the stacker. It provides a controlled environment for electrical equipment. Stackers are equipped with sophisticated control systems, which can be either semi-automatic or fully automatic. These systems enable precise control over the stacking process, contributing to efficiency and accuracy.

Technical Data

The detail capacity and other technical data of stackers can be customized by clients, the capacities of our stackers can be from 300 t/h to 21,500 t/h and boom length can range from 20 to 65 meters.

Technical Specification Value
Stacking capacity up to 21,500 t/h
Boom length 20 – 65 m
Belt width 600 – 2800 mm
Rail gauge  6 – 20 m

Note: Above data can be adapted and may vary according to client’s requirement.

Similar to all TechSolutions designed bulk material handling equipment, the operation modes of stackers can be local control & operation, manual operation, manual remote control, semi-automatic unmanned operation and full-automatic smart unmanned operation.

Stackers Performance

TechSolutions have successively delivered 360 sets of various types of stackers reclaimers including stackers, reclaimers, combined stacker reclaimer (excluding circular stockyard stacker reclaimer, more than 600 sets if including circular stockyard stacker reclaimer) to clients in mining & metal, power, petrochemical, ports & terminals and other industries.

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Circular Stacker Reclaimer

How Can We Help You?

If you would like to know more about the use of stacker in your industry, how they work, which solution is best for your business, or request technical documentation, just chat with our customer care centre:

Tel: +86 21 6890 6101
E-mail: service@techsolutions.com.cn

Alternatively, you can contact our sales team using contact form.

FAQs

1. What is a Stacker?
A stacker is specialized machine designed for the efficient stacking and management of large quantities of bulk materials, particularly in stockyard. These materials can include coal, minerals, ores, aggregates, and various other types of bulk commodities. The primary function of a stacker is to stack bulk materials in predetermined stacking methods or stockpiles, facilitating organized storage and easy reclaiming when needed. Stackers are core equipment in industries such as mining, coal-fired power generation, and metal manufacturing, port handling, etc.
Stacker is used to stack bulk materials transported by belt conveyor system to the stockyard. Bulk Materials transported by belt conveyor system are stacked to the stockyard through tripper car, chute and hopper, boom belt conveyor.
Stacker is an efficient machine for continuously stacking of bulk materials with particle size less than 300mm in storage yards of thermal power plants, ports and terminals, steel plants, coking plants, mines, alumina refinery plants and other industries.

2. How does a Stacker Work?
Stacker is high-capacity machine used for stacking and blending bulk materials. Working in two directions, a stacker can pile material onto two parallel stockpiles using a slewing and luffing boom. A rail-mounted stacker travels on two rails between the stockpiles. The stopping and starting sequence for the stacking operation is controlled either from the operator’s cabin or central control room.
When stacking, combine stacker moves along a predefined path over the stockyard, bulk materials transported by belt conveyor are distributed in even layers, creating a neatly organized stockpile. This process continues until the desired height or volume of material is achieved.

3. Applications of Stackers
Stackers are usded widespreadly across various industries where the efficient stacking and organized management of large quantities of bulk materials are essential, from Mining Industry (Stockpiling Ores), Power Generation (Coal Handling), Steel and Manufacturing (Raw Material Storage), Ports and Terminals (Bulk Cargo Handling), Cement Industry (Raw Material Handling),Aggregate and Quarrying (Stockpiling Aggregates),Chemical Industry (Bulk Chemical Handling),Pulp and Paper Industry (Wood Chip Handling),Fertilizer Industry (Fertilizer Handling), etc.

Technical Data

CAPACITY

up to 21,500 t/h

BOOM LENGTH

20 – 65 m

BELT WIDTH

600 – 2800 mm

RAIL GAUGE

6 – 20 m

Note: Above data can be adapted and may vary according to client’s requirement.