See

discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/266368065

Methodology to Calculate the Effective

Reclaiming Capacity of Rail-Mounted BoomType Bucket Wheel Reclaimer and
Stacker/Reclaimer
Article in Bulk Solids Handling April 2004

CITATION

READS

1,860

4 authors, including:
Dragan Komljenovic

Jacek Paraszczak

Hydro-Qubec

Laval University

62 PUBLICATIONS 258 CITATIONS

18 PUBLICATIONS 91 CITATIONS

SEE PROFILE

SEE PROFILE

Kostas Fytas
Laval University
36 PUBLICATIONS 227 CITATIONS
SEE PROFILE

All in-text references underlined in blue are linked to publications on ResearchGate,

letting you access and read them immediately.

Available from: Dragan Komljenovic

Retrieved on: 24 September 2016

D. Komljenovic, J. Paraszczak, K. Fytas, Canada and C. Drebenstedt, Germany

Methodology to Calculate the Effective

Reclaiming Capacity of Rail-Mounted
Boom-Type Bucket Wheel Reclaimer
and Stacker/Reclaimer
Summary
This paper focuses on the methodology to calculate the effective reclaiming capacity of railmounted bucket wheel reclaimers, and
stacker/reclaimers, for large-scale raw bulk material handling systems. Due to considerable
gaps in the theory on this subject, a principal objective of the work presented here was to develop a methodology destined to determine reclaiming capacity of these machines. It reflects
the relationship between the characteristics of
the equipment and the parameters associated
with its work environment. A function concerning
the rule of the boom-slewing motion was defined. It was based on the particular shape of
stockpiled material and the digging geometry of Fig. 1: Rail-mounted bucket wheel stacker/reclaimer with a slewing boom [21]
the machines. This function was subsequently
employed as a basis to work out a precise methodology for calthese operations has a considerable impact onto prices of final
culating the effective reclaiming capacity of the equipment
products. Therefore, bulk solids handling systems ought to be
analysed. Successful validation of the model developed was perefficient, reliable, highly productive and must enable a good maformed for the Quebec Cartier Mining (QCM) port facilities in Port
terial flow, at the least cost. This requires more efficient reclaimCartier. The paper concludes with some possible applications of
ing and stacking machines.
the results achieved in this study.
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 reclaim1 Description of the Problematic and
ing). The most frequently used ones are the rail-mounted boomtype machines, such as a stacker/reclaimer shown in Fig. 1. To
Objectives of the Research
simplify the text that follows, from now on these machines will
be referred to as R&S/R.
1.1 Introduction
Handling and transhipment of bulk solid materials plays an important role in modern economy. It is due, among other things,
to steadily increasing volume of raw materials being transported
from often remote mine sites on all continents to plants and facilities in both industrialised and industrialising countries. Cost of

During the reclaiming operation the bucket of such machines

follows a 3D trajectory defined by a combination of three elementary movements (Fig. 2):
Fig. 2:

Elementary movements of a bucket wheel reclaimer or stacker/reclaimer

in reclaiming operation [1]

DRAGAN KOMLJENOVIC, Ph.D., P.Eng., Production Advisor/Reliability Engineer,

Hydro-Quebec, 4900, boul. Bcancour, Bcancour (Quebec) G9H 3X3, Canada
Tel.: +1-819-298-2943 (Ext. 5032); Fax : +1-819-298-5092
E-Mail: komljenovic.dragan@hydro.qc.ca
Prof. Dr.-Ing., Dr.h.c. CARSTEN DREBENSTEDT, Professor in Opencast Mining
Technische Universitt Bergakademie Freiberg, Mining Institute, Gustav-Zeuner
Str. 1, D-09596 Freiberg (Sachs), Germany. Tel.: +49-3731-393-373;
Fax: +49-3731-392-524; E-Mail: drebenst@mabb-tu-freiberg.de
JACEK PARASZCZAK, Ph.D., Full Professor, Dept. of Mining, Metallurgy and Materials, Laval University, Quebec G1K 7P4, Canada; Tel.: +1-418-656-5103;
Fax: +1-418-656-5343; E-Mail: jacek.paraszczak@gmn.ulaval.ca
KOSTAS FYTAS, Ph.D., P.Eng., Full Professor, Dept. of Mining, Metallurgy and Materials, Laval University, Quebec G1K 7P4, Canada; Tel.: +1-418-656-5057;
Fax: +1-418-656-5343; E-Mail: kostas.fytas@gmn.ulaval.ca
Details about the authors on page XXX.

Vol. 24 (2004) No. 3 bulk solids handling

Reclaiming Capacity of Bucket Wheel Reclaimer

rotation of the bucket around its own axis at speed vr,

slewing of the boom around a vertical axis to a yard plane at
speed vzkr, and
travel of the machine on rails parallel to the pile at speed vtr.

ogy to calculate the performance of reclaiming and stacking operation of R&S/R, as well as the creation of a selection criterion
for these machines.

The stacking (stockpiling), as the second operation, can be carried out only by stacker/reclaimers. The machine travels alongside the stockyard where bulk material is stockpiled. Therefore,
one realizes the importance of developing a precise methodol-

1.2

Scope of the Work

At the early stage of the selection process of R&S/R, the

amount of information available is limited. Specifications pro-

Nomenclature
a

distance between the travelling axis of the R&S/R and the

pile toe [m]

tg

acceleration time of the boom or the machine [h]

tk

digging time in a cut [h]

tk(mod)

total digging time in a module [h]

tktot

total digging time in a stockpile [h]

tm

manoeuvring time of R&S/R in the reclaiming operation [h]

tmtot

total of all manoeuvring times in all modules of a stockpile [h]

area of an individual cut in a reclaiming operation [m2]

a1i

distance between the travelling axis and the near bench

edge [m]

a2i

distance between the travelling axis and the

far bench edge [m]

a1p

distance between travelling axis of the R&S/R and the near

bench edge, in the first reclaimed bench [m]

tod

returning time of the machine [h]

tpd

raising time of the boom [h]

distance between the travelling axis of the machine and the

stockpile-middle [m]

tpr

advancement time of the machine [h]

tr-st

operating (reclaiming) time [h]

tsp

lowering time of the boom [h]

ttr

displacement (travelling) time of the machine [h]

ast
b0

cutting width at the slewing angle 00 [m]

cutting width at the slewing angle [m]

c0

cutting depth at the slewing angle 00 [m]

cutting depth at the slewing angle [m]

bucket wheel diameter [m]

2d

distance between the rails of the runway [m]

dp

width of the pile top flat [m]

dpc

width of the pile top flat which is not still reclaimed [m]

di

width of the pile flat in the bench i [m]

dmp

width of the pile top flat full reclaiming block [m]

Er

bucket volume [m3]

Vz

reclaimed volume [m3]

gu

maximal slewing acceleration/deceleration of the bucket

wheel boom [m/s2]

distance between the rotating centre (slewing axis) and the

boom fixation [m]

gravitational acceleration; g = 9.81 m/s2

Yk

Hmax

maximal height of stockpiled material [m]

height of the boom fixation at the rotating centre of the machine [m]

height of stockpiled material [m]

pile slope angle []

height of the bench i [m]

angle of front slope []

Hr(g)

maximal positioning height of the bucket wheel axis [m]

Hri

positioning height of the bucket wheel axis in the bench i [m]

angle between the bucket wheel and the boom in horizontal

plan []

Lk

bucket wheel boom length [m]

1i; 2i

slewing angles of the boom - auxiliary variables []

Lsr

length of cutting edges in contact with material [m]

a1i

angle of the interval 3 []

angle of the interval 4 []

number of reclaiming benches in the pile

va2i

angle of the interval 2 []

ni

discharge frequency of buckets [1/min]

ua3i

nm

number of modules in the stockpile

k1i

angle of a maximal acceleration/deceleration of the boom inner bench side []

nr(i)

number of cuts in a bench

k2i

Qeff

effective reclaiming capacity [m3/h]

angle of a maximal acceleration/deceleration of the boom outer bench side []

Qex

exploitation capacity (reclaiming rate) [m3/h]

mi

angle of a maximal slewing speed of the boom []

current slewing angle []

ui

boom slewing angle - near side of the block in the bench i []

hi

Qt

theoretical capacity (reclaiming rate)

[m3/h]

[m3/h]

Tcal

total calendar time per year; Tcal = 8760 h

vk

slewing speed of the boom at the slewing angle [m/min]

vk1i

slewing speed of the boom at the end of the interval 2 [m/min]

vk2i

slewing speed of the boom at the end of the interval 3 [m/min]

vr

peripheral speed of the bucket wheel [m/s]

vtr

travelling speed of the machine [m/h]

min/max minimal/maximal slewing speed of the bucket wheel boom at

vzkr
the bucket [m/min]

Qth

technical capacity (reclaiming rate)

bucket wheel radius; r = D/2 [m]

vi

boom slewing angle - far side of the block in the bench i []

Rki

reclaiming outreach in the bench i [m]

vn

Rkn

reclaiming outreach in the lowest bench (n) [m]

boom slewing angle - far side of the block in the lowest

bench []

Sn

stockpile width on the ground [m]

txy

current slewing angle []

Snb

reclaiming block width - full block [m]

inclination angle of the boom in the bench i []

Suk

total stockpile width [m]

ui

contact angle between the bucket wheel and the reclaimed

material []

bulk solids handling Vol. 24 (2004) No. 3

2mm luft lassen

vided by manufacturers specify (among others) linear dimensions of the machine, and its theoretical output rate, usually expressed in tonnes per hour. It is more convenient to have the
later parameter in m3/h because the bucket volume Er and the
number of bucket discharges per unit of time ni are usually
known. In this case, the theoretical reclaiming rate is calculated
as follows:
Q t = 60 Er ni
(1)
The above value, however, is not the actual one that may be expected. Users should know the effective output rate (effective
capacity) for their planning schedule. This represents the actual
output of a reclaiming operation, and reflects influences of most
important factors, such as:
design parameters of the machine,
geomechanical factors (properties of bulk material), and
technological parameters (block shape, mode of operation).
These factors and influences may be presented in the manner
shown in Fig. 3.
Calculation procedures (models) used currently for R&R/S are
those derived from Bucket Wheel Excavators (BWE) theory. BWE
operates in blocks, in which only the cutting depth changes with
an increasing slewing angle of the bucket wheel boom. This
change may be described by the following rule (Fig. 4):
c = c 0 cos

vk

This is an important issue, since an inaccurate assessment of

design parameters of a R&S/R at the pre-select stage may have
negative (and expensive) consequences for a future user. Undesired excessive capacity usually involves higher capital and operating cost, whereas insufficient one may put in jeopardy the
efficiency of the whole bulk material handling system.
A precise assessment of the effective reclaiming capacity becomes then one of the crucial points of the selection process.

1.3

(3)

Principal Objective of the Work

Given some drawbacks and gaps of currently used models describing the reclaiming function of rail-mounted bucket wheel
reclaimer and stacker/reclaimer (R&S/R), it is justifiable to investigate a new approach.
In this context, the study presented here will focus on development of an accurate calculation methodology to determine
R&S/R reclaiming capacity.

(2)

During the slewing operation, the height of cut remains unchanged. In order to compensate for this volume loss and to
keep the buckets full, the slewing speed of the bucket wheel
boom should increase reciprocally:
v
= k0
cos

slewing angle (Fig. 5). Therefore, a new guiding rule, reflecting

particularities of reclaiming should be developed.

Methodology to Calculate the

Effective Reclaiming Capacity of
Rail-Mounted Boom-Type
Bucket Wheel Reclaimers and
Stacker/Reclaimers (R&SR)

Reclaiming operation modes may be classified into two categories: a bench (more frequently used) or a modular-type (see
Fig. 6) [12].
Fig. 5:

Typical block shape in reclaiming operation [16]

This approach is not adequate in the case of a reclaiming operation carried out by R&R/S, where cutting height varies with the
Theoretical capacity

Input
(main bucket wheel design parameters)

Transitional function

Influence factors on effective capacity

- geomechanical/natural parameters
- technological parameters
- other design parameters

Effective capacity
(Output)
Fig. 3:

Influential factors on effective capacity

Fig. 4:

Change of cutting depth with an increasing slewing angle [3]

Vol. 24 (2004) No. 3 bulk solids handling

2mm luft lassen

The principal type of a reclaiming operation is the block work.

There are two block shapes (Fig. 7):
narrow block, and
full block.
A combination of these two block types may also occur. Fig. 7
that illustrates geometrical relationships is a basis for a detailed
study presented below.
2.1.1 General Relationships

Fig. 6:

Types of reclaiming mode [12]; a) bench-type b) modular-type

In order to develop a precise methodology of the reclaiming performance of a rail-mounted bucket wheel R&S/R, it is necessary
to investigate and define the rules governing cut dimensions
variability both in horizontal and vertical plane. Following them,
the rule for a bucket wheel slewing speed would be defined.
This will enable determination of the transitional function (see
Fig. 3), and an exact calculation of effective reclaiming capacity.

2.1

Geometrical Relationships in
Block-Reclaiming Operation

As mentioned before, development of the adequate methodology to calculate the effective capacity of a reclaiming operation
is the main objective of this research.

This section gives equations for calculation of main geometrical

relationship between the linear parameters of the machine such
as: bucket wheel boom length, wheel diameter etc, and block
geometry.
Reclaiming outreach in the bench
According to design parameters of the machine and block dimensions, this parameter is calculated in the following manner:
R ki = Lk cos i + X + r cos r sin ui

(4)

External slewing angles

When the boom reaches the outer slope of the block, it is
slewed at a certain angle from the travel axis of the machine.
This external slewing angle of the boom in the bench i, is defined in the following manner:
n

The first step consists of determining the main relationships between the linear dimensions of the machine and the geometry of
the bulk material block to be reclaimed.
Fig. 7:

(R kn r cos r sin un ) sinvn hj cot

vi = arcsin

j=i+1

R ki r cos r sin ui

(5)

Block-types in a reclaiming operation; a) narrow block, b) full block

bulk solids handling Vol. 24 (2004) No. 3

2mm luft lassen

Height change within the sector vi 2it < 2i (outer slope side)

Internal slewing angles

At the beginning of a bench at the inner side of the pile, the
bucket wheel boom is slewed at an angle called internal slewing angle. It is also measured from the travel axis of the equipment. Its numerical value is:
n

ht2i = hi

j=i+1

R ki r cos r sin ui

(6)

2.1.2 Variation of the Digging Height

Due to the shape of the pile, the cutting height in a reclaiming
operation varies. If the pile cross-section is triangular, the cutting height changes constantly in the first reclaimed bench. In
the case of a trapezoidal cross-section, this height remains constant in the flat top area. Since this variation involves capacity
losses, it is important to determine a rule to adjust the boom
slewing speed to compensate for them.
Although some losses are inevitable due to a machine design
(for example due to a limit of maximum slewing speed), it is feasible to minimize them. Fig. 8 will be used to determine the rule
of the digging height change. It is given as follows:
Fig. 8:

(7)

Height change within the sector 1i 1it < ui (inner slope side)

a + hj cot
ui = arcsin

vi t2i
vi 2i

ht1i = hi

t1i ui
1i ui

(8)

If the machine is operating in a full block, the cutting height

changes only within the sector 1i 1it < ui (inner slope side)
and Eq. (8) should be used.
2.1.3 Digging Geometry and the Technical Capacity
In order to further develop the methodology to calculate reclaiming performance, the technical capacity Qth and digging
geometry should be considered.
The former depends on natural (geomechanical) characteristics
of handled material, such as: digging resistance kL, swell factor of
material kr, and bucket fill factor kpu, cut dimensions (height,
depth, and width), and boom slewing speed.

Determining the cutting height change in reclaiming operation

Vol. 24 (2004) No. 3 bulk solids handling

2mm luft lassen

Relationships concerning the technical capacity and digging

geometry, developed for BWE [3,8,13,14,15,19,22] remain applicable for the case of R&S/R.
In this study, they are adopted after a slight modification, and integrated into the methodology. The rationale of these relationships may be found in the above mentioned references.
Besides technical capacity and specific digging force, the following parameters of digging geometry are taken into consideration:
Total length of cutting bucket edges Lsr;
Optimal ratio between cutting depth and width (c/b)opt;
Actual cutting depth and width, as function of the technical
capacity c0, b0;
Peripheral digging force of the bucket wheel Pk;
Optimal slewing speed at the beginning of a bench vk0.

speed chart, see Fig. 9b. The slewing speed is defined by

angle mi .
6. Maximal linear acceleration/deceleration in the far side pile
slope (Interval 6). The far side pile slope is defined by angle k2i .
Intervals 4, 5, and 6 cover the area of the inner pile slope (D - A
in Fig 8). In order to maximise reclaiming capacity, it is necessery
to optimise the boom slewing speed in intervals 2, 3, and 4.
2.2.2 Rule of Slewing Speed Change by Intervals
Rule of slewing speed change at interval 2 (1i < 1it a3i )
Within this interval, both cutting depth and height vary. In order
to maintain constant capacity, the slewing speed of a bucket
wheel boom should then vary in a reciprocal manner. The formula is as follows:

There are two principal shapes of the bucket: trapezoidal and

semi-rounded. For more details, consult above mentioned references.

v1t
ki = vk1i
Fig. 9:

2.2

Rule of Slewing Speed Guidance

in a Narrow Block

The next stage consists in determining the rule for boom slewing
speed guidance. As mentioned before, the dimensions of a cut,
dug by the bucket wheel, change in horizontal and vertical planes.

(1i ui ) cos 1i
(t1i ui ) cos t1i

(10)

Change of bucket wheel slewing speed

a) maximal design speed is reached
b) maximal design speed is not reached

a)

On a horizontal plane, the bucket wheel cuts a sickle shaped cut,

which changes accordingly to the rule given by Eq. (2), see Fig. 4.
On a vertical plane, the cut shape depends on the pile crosssection (triangular or trapezoidal). The rule of change is defined
by Eqs. (7) and (8) (see Fig. 8).
Since the objective is to maximise the capacity, the boom slewing speed ought to vary to compensate for changes in cut dimensions.
Its general form is as follows:
vk = (, h)

(9)

For the purpose of this research, an original methodology for

determining the rule of boom slewing speed change (guidance),
as a function of the cut-dimension variations mentioned above,
is developed.
2.2.1 Intervals of Slewing Speed Change
With regard to the above, and design limits of R&S/R, such as
the maximal slewing speed, and bucket dimensions, the following intervals may be distinguished (see Fig 9):

b)

1. Maximal linear boom slewing acceleration/deceleration in the

inner slope (Interval 1). The inner slope is defined by angle k1i .
2. Automatic slewing speed regulation in the area where the cutting height changes in the near-pile slope (Interval 2); intervals
1 and 2 cover the area of the inner slope marked by B - C in
u
Fig. 8. The near-pile slope is defined by angle a3i
.
3. Automatic slewing speed control in the area of a constant
cutting height (Interval 3), where only the cutting depth
varies. It is defined by angle a1i . In Fig. 9, this interval is located at the area C - D. If the pile has a triangular shape, this
interval is absent in the first /highest bench.
4. Automatic slewing speed regulation in the area where the
cutting height changes in the outer slope (Interval 4). The
v
outer slope is defined by angle a2i
.
5. Maximal slewing speed limited by maximal design limit of the
slewing speed (Interval 5). When such limit is not reached,
this interval will disappear from Slewing angle - slewing

bulk solids handling Vol. 24 (2004) No. 3

2mm luft lassen

Rule of slewing speed change at interval 3 (2i < i 1i )

a3i = ui +

Within this interval, only the cutting depth varies. As the cutting
height remains constant, the slewing speed is as follows:
v ki = vk1i

cos 1i
cos i

A 1i
(a3i ui )2 COS2a3i

(19)

where :
(11)
A 1i =

v2k1i (1i ui )2 cos 21i

7200 gu R ki

(20)

At the limit of this interval, the slewing speed reaches a value of:
vk2i = vk1i

cos 1i
cos 2i

(12)

Rule of slewing speed change at interval 4 (a2i < i 2i )

At this interval both the cutting depth and height vary. The slewing speed rule encompasses both variables:
v2t
ki = vk1i

(vi 2i ) cos 1i
(vi t2i ) cos t2i

(13)

Determining angle a2i , borderline between intervals 4 and 6

(vi < 2it < 2i )
This angle (see Fig. 9 b) defines a borderline between intervals 4
and 6. If the interval 5 (maximal constant slewing speed, Fig. 9a)
exists, the calculation of this angle is different and will be shown
later. As in the previous case, one observes that the slewing
speed at the limit of interval 4 must be equal to that at the beginning of interval 6. They coincide at point P. Therefore, the
equations become:
v3 = gu t6

Following this analysis, the optimal rule of the boom slewing

speed change defined for intervals 2, 3, and 4 allows to achieve
maximal reclaiming capacity. In practice, if the reclaiming operation is automated, the guidance for the slewing speed is based on
both the engaged power of the motor installed the bucket wheel
and on the material output recorded on the boom conveyor.

v4 = vk1i

(22)

Since at the point P it is v3 = v4, the two equations can be compared and resolved with regard to t6:

2.2.3 Angles of Automatic Slewing Speed Guidance

t6 =

After the above analysis there still remain two transition points
between intervals (borderlines) to be determined, namely: at the
border of intervals 1 and 2, as well as 4 and 5 (Fig. 9 a), or 4 and
6 (Fig. 9 b). Other borderlines have been determined in the previous chapter.

(vi 2i ) cos 1i
60 (vi a2i ) cos a2i

(21)

vk1i (vi 2i ) cos 1i

60 gu (vi a2i ) cos a2i

(23)

where:
t6 slewing-motion time in interval 6 [s]
In interval 6, the following is the equation of slewing motion:

Angle a3i , borderline between intervals 1 and 2 (1i < 1it < ui )
This angle (see Fig. 9) defines a borderline between intervals 1
and 2. Obviously, the slewing speed at the limit of the acceleration (deceleration) interval 1 must be equal to that at the beginning of the interval 2. They coincide at point Q (Fig. 9). According to these, it may be written as follows:
v1 = gu t1
v2 = vk1i

(1i ui ) cos 1i
60 (a3i ui ) cos a3i

(14)

vk1i (1i ui ) cos 1i

60 gu (a3i ui ) cos a3i

a2i = vi k2i

(24)

(25)

Integrating Eqs. (23) and (24) into Eq. (25), the following equation is obtained:
a2i = vi

(16)

gu t62
2 R ki

The angle of the automatic speed control is calculated in the following manner (Fig. 9b):

(15)

Since at point Q it is v1 = v2, these two equations can be compared and resolved with regard to t1:
t1 =

k2i =

v2k1i (vi 2i )2 cos 21i

7200 gu Rki (vi a2i )2 cos 2a2i

(26)

It is also necessary to verify if the maximal design slewing speed

max has been reached or exceeded
of the bucket wheel boom vzkr
at the angle a2i.
Note: Eqs. (19) and (26) should be solved by using a of numerical method.

where:
t1 motion time in interval 1 [s]

2.3

In interval 1 (maximal linear acceleration or deceleration), the

equation of slewing motion is as follows:
k1i

g t2
= u 1
2 R ki

(17)

The angle of the automatic speed control is calculated in the following manner (Fig. 9):
a3i = ui + k1i

(18)

Integrating Eqs. (16) and (17) into Eq. (18), the following equation is obtained:

Digging Time in a Narrow Block Reclaiming

Operation

Once the angles of automatic speed control are defined, it becomes possible to determine the digging time of the bucket
wheel in a sickle cut.
Digging time in interval 1 (defined by angle k1i, see Fig. 9)
Slewing speed at point Q on the borderline between intervals 1
and 2
(1i ui ) cos 1i
vQki = vk1i
(27)
(a3i ui ) cos a3i

Vol. 24 (2004) No. 3 bulk solids handling

2mm luft lassen

This slewing speed at point Q is calculated using Eq. (10) by

substituting.

t 4i

vk1i (vi 2i ) cos 1i

dt = 60 R

vi
a2i

60 R ki

vQki
t1i =
60 gu

(28)

Digging time in interval 2 (defined by angle ua3i, see Fig. 9)

(1i ui ) cos 1i
60 (t1i ui ) cos t1i

(29)

1i

dt = 60 R
ki

t1i

a3i

cos t1i dt1i

2i

t
2i

cos t2i dt2i

60 R ki (vi a2i ) sina2i cos a2i

vk1i (vi 2i ) cos 1i

cos t1i dt1i

a3i

60 R ki (1i ui ) sin1i + cos 1i

t2i =
vk1i (1i ui ) cos 1i

(34)

60 R ki (vi 2i) sin2i cos 2i

vk1i (vi 2i ) cos 1i

Eq. (34) represents the digging time in interval 4.

In interval 5, the slewing speed of the bucket wheel boom

reaches the maximal design value max
zkr (see also Fig. 9a). The
angle mi is calculated as follows:
m = vi k2i m
ki

1i

60 Rki ui

t
t
2i d2i

Digging time in interval 5

(if the latter exists, it is defined by angle mi)

whose solution is the following:

t 2i

cos

2i

t4i =

The slewing motion of the bucket wheel boom in this interval

(1i < t1i a3i ) can be described by the following differential equation:

vk1i (1i ui ) cos 1i

ki

Acceleration (deceleration) time - digging time in interval 1

R ki dt1i = vk1i

a2i

If an interval 5 exists, the angle k2i defining the interval 6 (see

Fig. 9a) is calculated according to the equation of slewing motion in this interval (6):
t5i =

(30)

60 R ki (a3i ui ) sina3i + cos a3i

vk1i (1i ui ) cos 1i

(35)

vmax
zkr
60 gu

Rki k2i =

gu t5i2
2

(36)

(37)

These equations give the following solution for the angle k2i:
Eq. (30) represents the slewing motion time (synonymous to
digging time) of the bucket wheel boom in interval 2.
Digging time in interval 3 (defined by angle a1i = 2i - 1i, see
Fig. 9)
In this interval (2i i 1i ), the motion of the boom is described
by the following differential equation:
R ki di = vk1i

cos 1i
dt
60 cos i

(31)

The solution is obtained in the following manner:

t 3i

2i

60 R ki

cos i di = vk1i cos 1i

dt

t5i =

60 mi R ki
vmax
zkr

(vi 2i ) cos 1i
(vi a2i ) cos a2i

(32)

The following differential equation describes the slewing motion:

The solution is as follows:

bulk solids handling Vol. 24 (2004) No. 3

(40)

This represents slewing speed at the point P (border of interval

6) calculated by means of Eq. (13), by substituting.

Digging time in interval 4 (defined by angle va2i, see Fig. 9)

(vi 2i ) cos 1i
60 (vi t2i ) cos t2i

(39)

It is the interval of maximal linear acceleration (deceleration) on

the outer side of a stockpile. In the absence of interval 5, the calculation is carried out according to Fig. 9b. The slewing speed
at the point P has the following value:

The digging time is calculated in the following manner:

t6i =

R ki dt2i = vk1i

(38)

Digging time in interval 6 (defined by angle k2i)

vPki = vk1i

and finally, the digging time in this interval:

60 R ki
(sin2i sin1i )
vk1i cos 1i

2
(vmax
zkr )
7200 gu R ki

The digging time in interval 5 is expressed as:

1i

t3i =

k2i =

(33)

vPki
60 gu

(41)

If the interval of maximal slewing speed (interval 5) exists, this

time becomes:
vmax
t6i = zkr
(42)
60 gu
Total digging time in a cut
The total digging time is given as the sum of individual digging
times by sectors. It is calculated as follows:

2mm luft lassen

tk(i) =

ji

Reclaimed volume of a cut in a narrow block

(43)

j=1

With total digging time in a sickle cut determined, an important

stage in development of methodology to calculate the reclaiming performance (capacity) is achieved.

According to Figures 7a and 8, it may be written that:

Vz(i) =

R ki hi c 1i sinvi + sin2i (sinui + sin1i )

(45)
2 cos 1i

Full block reclaiming operation

Reclaimed volume in a cut in a full block

The rule of slewing speed guidance in a full block may be determined in a similar manner. In this case (see also Fig. 9b), a
R&S/R operates in the block where the cutting height on the
outer side of a pile remains constant. The variation in the cutting
height on the inner side of a stockpile follows the same pattern
as in a narrow block. Consequently, the slewing speed rule
changes must be defined. Intervals of slewing speed change in
a full block operation are determined using the same approach
as the one employed for the narrow-block reclaiming operation.

Regarding figure 9b, reclaimed volume is as follows:

2.4

Effective Reclaiming Capacity

Effective capacity in reclaiming operation expresses a real output of a system with a working reclaimer or stacker/reclaimer
(R&S/R). It depends on equipment design, technological parameters, as well as geomechanical properties and characteristics of material handled. A general formula is as follows:
Q eff =

V
tk + tm

(44)

Vz(i) =

At the beginning, a study concerning the effective capacity in a

sickle cut will be done. The next stage will consist in determining of effective reclaiming capacity in an entire stockpile.
2.4.1 Effective Reclaiming Capacity in a Cut
Reclaimed volume in a cut
It corresponds to the volume dug by the bucket wheel during a
slewing cycle from the inner to the outer side of a stockpile. In
a narrow-block, it is calculated differently than in a full block.
Fig. 10: Plan for determining the manoeuvring time of a R&S/R in a modular reclaiming type

(46)

After calculating the volume reclaimed in a cut, the manoeuvring

time must be determined.
Manoeuvring time in a cut
As previously mentioned, this is the time elapsed on manoeuvring motions of a machine in a digging cut (with digging time
excluded). It does not depend on the block-type (narrow or full
block) in a reclaiming operation. In the following, all components
of this time will be defined.
Manoeuvring time in the bench-type reclaiming operation
In a bench-type of reclaiming operation (see also Fig. 6a), a
R&S/R performs only one manoeuvre: an advance for a cutting
depth. It is calculated as follows:

Eq. (44) represents the mathematical form of the transitional

function shown in Fig. 3.
The manoeuvring time tm accounts for manoeuvres of a given
machine in a digging cut, such as positioning a R&S/R during a
reclaiming operation. Depending on reclaiming mode (bench or
modular-type), this time is calculated differently. It does not depend on the block-type (narrow or full block) in a reclaiming operation.

R ki hi c 1i sinvi 0.5 (sinui + sin1i )

cos 1i

tm(i) = tg +

c max (i)
vtr

(47)

where:
cmax(i) depth of the machines advance (see Fig. 4).
c max(i) =

c 1i
cos 1i

(48)

Manoeuvring time in the modular-type reclaiming operation

In a modular-type reclaiming operation (see also Fig. 6), the machine performs several manoeuvres (see Fig. 10).
The machine begins at the top of a stockpile by taking a cut.
The cut depth varies from case to case. At the completion of a
bench, the reclaimer moves back at the distance of the advance, plus an additional distance to clear the angle of a lower
bench face, and to assure a longitudinal terrace geometry which
is stable for reclaimed material. The boom is then lowered to the
next bench and a new reclaiming cycle begins. This sequence is
repeated for each bench in a reclaiming module. When the last
cut in the last bench (the lowest bench) has been completed,
the bucket wheel boom is raised to the highest (first) bench to
recommence a new cycle in a new module. According to the
above description, the total manoeuvring time is composed of
the following individual actions (see also Fig. 10):
raising the boom tpd (between points 8 and 9);
displacement of the machine ttr (see an explanation below);
advance of the machine tpr (between points 1-2, 4-5, and 7-8);
return of the machine tod (between points 2-3, and 5-6);
lowering the boom tsp (between points 3-4, and 6-7).
These time components may easily be determined using Fig. 10.
Total manoeuvring time in a module
It is equal to the sum of all individual manoeuvring times:

Vol. 24 (2004) No. 3 bulk solids handling

2mm luft lassen

tm = ttr + tpd +

n1

pr(i)

i=1

od(i)

i=1

2.5

(49)

sp(i)

i=2

It may be defined as a real performance of a R&S/R over a period of time (usually one year) in actual local conditions. Besides
the factors related to effective reclaiming capacity (design, geomechanical and technological), it may also be affected by organizational, climatic, subjective, market, etc. factors [15]. It may
be said that it depends on equipment availability and its contributing factors (corrective and preventive maintenance, delays,
etc.), its utilization during working hours (operational delays,
statutory breaks, standby-time, etc.) as well as work scheduling
(working hours/shifts per day, workdays per year, etc.). An example of equipment time split for a calendar year may follow a
pattern given in Fig. 11 [2].

With total manoeuvring time expressed as a function of the type

of reclaiming operation, effective reclaiming capacity may be
calculated according to Eq. (44).
2.4.2 Effective Reclaiming Capacity
If a R&S/R operates in a bench-type of operation, its effective
reclaiming capacity in a cut can now be calculated according to
Eq. (44) where the cut volume is given by Eqs. (45) or (46). If,
however, a R&S/R carries out reclaiming operation of a modular-type, the effective reclaiming capacity of this machine in a
cut, may now be calculated according to Eq. (44). However, for
this type of operation, one talks rather about the effective capacity in a module than in a cut. The volume of a module may be
calculated as follows:

In order to increase the efficiency of operations, delay times (operation, maintenance) and idle time should be minimised. The
yearly reclaiming productivity (operational capacity) is given as
follows:
Q eff = Q eff T0
(52)

Vmod =

r(i)

Vz(i)

(50)

where:

i=1

Qeff effective reclaiming capacity in a cut or in a module [m3/h]

The reclaimed volume depends on stockpile shape, digging

time changes with the block form (narrow or full), whereas manoeuvring time depends on the reclaiming mode (bench-type or
modular-type operation). The formulas to calculate these parameters are developed above.

To actual operating time of the machine per year [h/year]

The level of working and operating time depends on internal and
external conditions in a location:
External conditions
- Needs for material handled
- Market fluctuation
- Input capacity from consumers (end-users)
- Frequency of reclaiming operation within a period of time
- Climate and weather conditions
- Type and properties of material handled
- Requested level of the environmental protection
Internal conditions
- Synchronisation between material inflow and outflow
- Effective reclaiming capacity
- Organisational efficiency of reclaiming and maintenance
operations
- Stockpile layout
- Skills and training of the personnel

2.4.3 Reclaiming Performance in the Entire Stockpile

The methodology to calculate reclaiming performance determined previously takes into consideration the effective reclaiming capacity of a R&S/R in a cut, or in a module. However, in
order to calculate a real output from a stockpile, the entire manoeuvring and digging times concerning this stockpile, have to
be considered. The effective reclaiming capacity regarding the
entire stockpile is calculated as follows:
Q eff st = 3600

Average Operational Performance Over

a Period of Time

Vd
tr st

(51)

where:
Vd volume of a stockpile [m3]
tr-st operating time in a stockpile [s]
Fig. 11: Diagram showing basic equipment time elements

Total calendar time

Tcal
8760 hours

Working time
Tw

Operating delays
Td

Down time
Tdw

Operating time
To

Pure digging time

Tk

bulk solids handling Vol. 24 (2004) No. 3

Maintenance delays
Tmd

Manoeuvring time
Tm

Idle time
Tidl

Corrective and preventive

meintenance time
Tr

Scheduled repair
Tsr

Unscheduled repair
Tdw

10

2mm luft lassen

These conditions may also vary from case to case and depend
on the location of a stockpile, as well as its purpose and organisational level. Productivity can be improve by acting on internal
conditions and optimisation ought to be done at the local, internal, and organisational level. By determining relationships connecting the most important influence parameters (design, technological, natural, organizational), a R&S/R user or designer will
be able to improve performance of the machine in reclaiming
operation. Obviously, by increasing the performance (capacity),
a lower operation cost will be reached.

3.1

Model Validation on Site with a

Working Stacker/Reclaimer Example:
The Qubec Cartier Mining Company
General Overview

The validation of the developed model was carried out at the

Qubec Cartier Mining company (QCM), or more precisely at its
deep sea port in Port Cartier (province of Quebec, Canada).
General data have been obtained by courtesy of the communication department.
QCM is one of the leading producers of iron ore products in
North America, and exporter to the USA, Europe and Asia. It
operates an open-pit mine and a crusher/concentrator facility
capable of producing 18 million metric tonnes of iron ore concentrates annually at Mont-Wright, close to the city of Fermont
in Northern Qubec. The company operates also a pellet-plant
in Port-Cartier, Qubec on the north shore of the Gulf of St.

Lawrence. Its annual production capacity is about nine million

metric tonnes of iron ore pellets. Iron ore concentrates and pellets are subsequently loaded on ships and delivered to customers. Pellets at Port Cartier stockpiles are handled by a
3ST46x140 stacker and a 3RP26x168 reclaimer, both from
Stephens Adamson. Iron ore concentrates are handled (stockpiled and reclaimed) by a ThyssenKrupps Ldc (360x1000)/52
combined stacker/reclaimer. Stacking of concentrates is performed using a chevron method, whereas a windrow method is
used for pellets. The latter is employed to avoid a segregation of
pellets having various corn sizes. Dimensions of a typical stockpile cross-section are shown in Fig. 12. The reclaiming operation is performed using a modular type operation.

3.2

Validation of the Calculating Methodology

Validation of the methodology has been performed for the

ThyssenKrupp machine. A typical shape of a reclaimed block is
shown in Fig. 13. It is necessary to mention that the machine operates in a combined narrow/full block, modular-type reclaiming
operation. A usual depth of the machine advance in a module is
L = 15 m. However, other depth advances may occur as well.
Benches 1 and 2 are reclaimed in a narrow block, while
benches 3, 4 and 5 in a full block operation (see Fig. 13). This
way, a maximal efficiency of the reclaiming operation is assured.
Height of the first bench is usually 4.4 m (according to the rule
h1 0.7D), whereas that of the others 3.9 m.
For the conditions and dimensions specified above, effective reclaiming capacity, calculated accordingly to a newly developed

North side

South side
44

21

10
5

84

60
90

Fig. 12: Typical stockpile cross-section

Fig. 13: Usual block shape during the reclaiming operation of the KRUPP machine at Port Cartier

11

Vol. 24 (2004) No. 3 bulk solids handling

2mm luft lassen

geomechanical properties of bulk material (including its digging resistance), and

technological parameters (block shape and mode of operation).

methodology is Qeff = 766.2 m3/h. However, this capacity varies

with a changing depth of the advance (see Table 1). It is due to
a relative increase of manoeuvring time in total operating time.

3.3

First, the influence of the main design and geomechanical parameters was defined. Subsequently, effective reclaiming capacity was determined. In addition to design and geomechanical
parameters, the influence of technological factors should be
taken into consideration. These are related to the digging and
manoeuvring time in a block. A complex mathematical analysis
was used to develop an appropriate methodology for calculating effective reclaiming capacity.

Actual Achieved Performance of the Machines

Records of operating performance exist for each machine at the

site for their whole operating life.
Moreover, the records for the last 12 months, and the period of
time since the last overhaul of the machine, are displayed separately. All data is kept on a computer system which manages
the entire operating data. Detailed information has been collected from 1997 to August 2000. Tab. 2 gives reached results
of the KRUPP machine.

Validation of the methodology performed on the operating

ThyssenKrupp stacker/reclaimer at QCMs Port Cartier harbour
facilities clearly confirms the applicability of this approach in actual conditions. The difference between calculated and actual
capacity, recorded over four years varies within a margin of 1.5
%. Based on these results, it may be concluded that the developed methodology is fully applicable for this purpose.

Validation of the methodology performed on the KRUPP

stacker/reclaimer operating in Port Cartier (QCM), clearly shows
the applicability of this approach in actual conditions. The difference between calculated and actual capacity, recorded over
four years varies within a margin of 1.5% (compare results in
Tables 1 and 2).

Anticipated Research Benefits

Final research results are applicable for the following purposes:
1. Pre-selection of a machine with regard to its acquisition; a future user should accurately calculate effective reclaiming rate
of a R&S/R, and make sure whether the machine under consideration matches capacity targets.

Conclusions

The research presented here has been focused primarily on

reclaiming capacity calculation of rail-mounted bucket wheel
reclaimers, and stacker/reclaimers (R&SR). The effective reclaiming capacity represents an actual output of this operation
with regard to its influencing factors, such as:

2. The follow-up of R&S/R in the reclaiming operation; if large

capacity variations and deviations from planned capacity
exist, verification ought to be performed to determine possible roots of problems, and solve them. This also helps maintain operating cost of the machine low.

design parameters of the machine,

3. Production scheduling; for operating R&S/R, the effective

capacity may be calculated precisely for production scheduling purposes over an analysed time period. This enables a
maximisation of the machines performance.

Table 1: The change of the effective reclaiming capacity as a function of the depth
of the advance L (ThyssenKrupp stacker/reclaimer)

Qeff (m3/h)

Li (m)

Qeff(L =15 m)/Qeff(Li) Difference

(%)
(%)

4. Analysis of potential benefits and assessment of impact of

possible design modifications onto performance of an existing machine leading to a choice of the best alternative.

5.0

743.14

96.99 %

7.5

753.88

98.39 %

-1.61 %

10.0

759.59

99.14 %

-0.86 %

12.5

763.97

99.71 %

-0.29 %

15.0

766.19

100.00 %

0.00 %

17.5

767.81

100.21 %

0.21 %

20.0

769.05

100.37 %

0.37 %

22.5

770.40

100.55 %

0.55 %

[1]

25.0

771.14

100.65 %

0.65 %

Tab. 2:

5. Development of a new machine (model) by manufacturers of

reclaimers and stacker/reclaimers. Performance of the new
model can be calculated precisely for different conditions of
application in order to optimise its design. This way, the best
alternative may be identified.

References
BERGONZOLI, A. and C. FERRETTI: Calculation Program for
the Analysis of the Performance of Boom-Type Reclaimers; Stacking, Blending & Reclaiming of Bulk Materi-

Operating parameters of the KRUPP stacker/reclaimer

Item

1997

1998

1999

2000
8 months
(yearly basis)

Mean
value

Standard
deviation

Working time (h)

1 450

1 058

1 429

2 223

1 540

490

Material handled
(metric tons)

2 875 862

2 132 834

2 528 075

4 404 372

2 985 286

993 562

Material handled
(m3)

1 106 101

820 321

976 337

1 693 989

1 148 187

382 139

Performance (tm/h)
(B/A)

1 983

2 017

1 769

1 982

1 938

114

Performance (m3/h)
(C/A)

763

776

680

762

745

44

bulk solids handling Vol. 24 (2004) No. 3

12

2mm luft lassen

als, Volume B/94,Trans Tech Publications, 1994, pp. 95108.

[2]

[3]
[4]

[5]

COLLINS, J.-L.: Simple ways for reducing equipment queuing time at a repair shop in an open pit operation; CIM Bulletin, October, 1988.
DURST, W. and W. VOGT: Bucket Wheel Excavator; Trans
Tech Publications, 1988, 378 pp.
FARIA DE, R., W. KIKUTI and M. MILANI: Stacker/Reclaimer
Design Using CAE, Stacking, Blending & Reclaiming of
Bulk Materials; Volume B/94, Trans Tech Publications,
1994, pp. 109-114.
GERLACH, K.-H.: Unmanned Operation of Stockyard Machines; Siemens AG (Internal document), 1999, Erlangen,
12 pp.

[6]

KENNEDY, B.A.: Surface Mining, 2nd Edition, Society for

Mining, Metallurgy and Exploration, Publications Sales ME,
P.O. Box 625002, Littleton, CO 80162-5002, USA, 1990
(ISBN 0-87335-102-9).

[7]

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.

[8]

KOMLJENOVIC, D.: Izbor osnovnih parametara sistema

hidraulicni rotorni bager samohodni transporter u
slozenim rudarsko-geoloskim uslovima (na primjeru PK
Dubrave) (MSc Thesis), University of Belgrade, 1991, 136
pp.

[9]

KORZEN, Z. and K. DUDEK: Mechanics of Gravitational Discharge of Cell-Less Bucket Wheels in Reclaiming Machines; Stacking, Blending & Reclaiming of Bulk Materials,
Volume B/94,Trans Tech Publications, 1994, pp. 121-132.

[19] STRZODKA, K., J. SAJKIEWICZ and A. DUNIKOWSKI: Tagebautechnik-Band I; VEB Deutscher Verlag fr Grundstoffindustrie, Leipzig, 1979.
[20] WIECZOREK, A.: Schwenkgeschwindigkeitregelung bei
Schaufelradrckladern (Internal Information); Company
Sandvik Roxton, Finland and Austria, 2000, p.1.
[21] WHLBIER, R.H.: Stacking, Blending, Reclaiming, Trans
Tech Publications, 1977, 858 pp.
[22] ZIVKOVIC, S.: Istrazivanje osnovnih parametara kompaktnog
rotornog bagera i tehnologije njegovog rada u slozenim
rudarsko-geoloskim uslovima (PhD Thesis), University of
Tuzla, Tuzla, 1992.
[23] Technical documentation of the mining company Qubec
Cartier, Port Cartier, Quebec, Canada.

[10] KULWIEC, R.A.: Materials Handling Handbook, John,

Wiley&Sons, 2nd Edition, Sponsored by The American Society of Mechanical Engineers and The International Material Management Society, New York, Chichester, Brisbane,
Toronto, Singapure, 1985. 1485 pp.
[11] MLLER, D.: Kohlenversorgungsmanagement Betriebserfahrungen mit einer voll-automatisierten Haldenbewirtschaftung, 6th International Symposium Continuous
Surface Mining, Freiberg, 2001, pp. 399-410.
[12] OYLER, J.F.: The Basis for Bucket Wheel Stacker/Reclaimer Design Philosophy; Stacking, Blending, Reclaiming, Trans Tech Publications, 1977, pp. 141-160.
[13] PAJER, G., M. PFEIFFER and F. KURTH: Tagebaugrossgerte
und Universalbagger, VEB Verlag Technik, Berlin, 1979.
[14] PARTZ, K.E.: Krftmessung an Schneiden von Schaufelradbaggern (Dissertation); Fakultt fr Bergbauingenieur- und
Vermessungswesen, University of Karlsruhe, Karlsruhe,
1985.
[15] POPOVIC, N.: Naucne osnove projektovanja povrsinskih
kopova, NIRO Zajednica NISRO Oslobodjenje, Sarajevo,
1984, 971 pp.
[16] PRINS, G., J. VAN LADESEIJN and R. FORTMAN: Concept of a
Walled-in Storage System for an Import Coal Terminal;
Stacking, Blending & Reclaiming of Bulk Materials, Volume
B/94, Trans Tech Publications, 1994, pp. 175-186.
[17] SCHMITZ, E.: Automatic Reclaiming of Bulk Solids; Stacking, Blending, Reclaiming, Trans Tech Publications, 1977,
pp. 285-292.
18] SCHNEIDERSMANN, E.O.: Design and Function of the Bucket
Wheel; Stacking, Blending, Reclaiming, Trans Tech Publications, 1977, pp. 161-170.

13

Vol. 24 (2004) No. 3 bulk solids handling