‘Telestack mobile stockyard management systems — stockpiling, reclaiming, truck unloading and link conveyors’
Telestack Limited specializes in the design, manufacture and installation of a complete range mobile stockyard management solutions for handling dry bulk materials. The range of equipment takes into consideration the ‘day to day’ operational capabilities of any stockyard system, consisting of stockpiling, reclaiming, truck unloading and linking conveyors. The Telestack equipment offers the operator cost-efficient solutions with unrivalled mobility and flexibility for any stockyard system.
 
CHANGING TRENDS:THE ALTERNATIVE TO THE STACKER/RECLAIMER SYSTEM
Typical operations in either developing a green-field site or upgrading a current stockyard operation would use a stacker/ reclaimer system for all their needs in terms of stockpiling and reclaiming of the bulk material. There are many manufacturers of stacker/reclaiming systems worldwide with varying associated capital costs depending on the customers requirements. Also, other substantial costs associated with this type of installation includes civil requirements, planning permission, government legislation etc.... which further increase the capital expenditure and time frame of the project.
The Telestack mobile systems can offer a cost-efficient alternative to stacker/reclaimer systems. Telestack equipment is designed for operators handling up to 5mt (million tonnes) year with a single system, degradation, segregation, contamination and compaction of the material. The robust heavy-duty design stockpiles up to 2,500tph (tonnes per hour) with the ability to handle a complete range of materials from coal/petroleum coke to iron ore which is ideal for multi-material stockyards. The mobility of the units is key to ensuring that production rates are maintained. Changing from one stockpile to another,Telestack’s integrated tracked dolly units (see Figure 2, left) ensure a highly mobile independent unit on harsh ground conditions within the stockyard. As seen in Figure 3 (below), the radial telescopic can be fed directly from the mobile link, reclaim and truck unloading conveyors to stockpile in the yard. The mobility allows the units to move back and around the stockyard to maximize the space/efficiency in the yard (see Figure 3) as required, while limiting downtime in the stockpiling process.
 
RECLAIMING: UTILIZING THE TELESTACK EQUIPMENT FOR YOUR RECLAIM SYSTEM
The Telestack equipment is ideally suited for either the stockpiling process or the reclaiming process, the multi functionality of the equipment limits the capital expenditure while still maintaining the required production capacities.
For those upgrading their current system from an older stacker/reclaiming system to a new design, the robust design of the Telestack equipment ensures that the operator can maintain their current tonnage per annum while limiting capital expenditure. For those developing new greenfield sites, the Telestack equipment is perfect for the initial ‘start-up phase’ of the project. The lower capital costs and no civil requirements/limited planning permission are the main advantages of the equipment in comparison to fixed stacker/reclaiming systems. The equipment allows the operator to begin phase one of the stockyard very quickly and easily, with lead times on Telestack equipment as short as 12 weeks from order. All Telestack units can be packed into 40ft containers for shipping globally and fully built on site within one week, with limited planning permission, civil requirements, and so forth.
 
RANGE OF MOBILE EQUIPMENT FOR STOCKPILING, RECLAIMING, TRUCK UNLOADING AND LINKING FOR AN EFFICIENT STOCKYARD SYSTEM
The mobile equipment allows for a range of stockpiling requirements depending on customer needs and height restrictions within the stockyard. The radial telescopic conveyors are heavy-duty stockpiling conveyors up to 58 metres length (190ft) which allow for a maximum stockpile height of 20 metres and up to 200,000+ tonnes (based on 1.6t.m3 density). The luffing (up/down) facility of the units allows the operator to use the units even in areas with restricted stockpile height. Also, the automatic PLC stockpiling system reduces the labour required to operate the equipment, while reducing the while still maintaining the production capacities. The mobility of the units allows the changeover from stockpiling mode to reclaiming mode very easily. When the stockpiles are built, the mobile reclaim hopper is situated next to the stockpile with multiple link conveyors utilized to limit the haulage distance of the wheel loaders. These link conveyors can then feed directly onto the over-land conveyor system. The mobile reclaim hopper and truck unloader can both be used to feed directly onto the overland conveyor system (if required), see Figure 5 (a & b, above) five below, which eliminates the double of the material. The mobile truck unloader can also be fed directly from trucks in the stockyard to feed the overland conveyor system, again to increase production capacities during the reclaiming process. The mobile reclaim hopper, truck unloaders and link conveyors, already used in the stockpiling process give the operator the complete package for a efficient stockyard system. The customized nature of the Telestack units ensures they meet the needs of any application, with capacities up to 2,500tph for both stockpiling and reclaiming. The overall benefit in the reclaiming process is the limitation of haulage distance of the wheels loaders/trucks to reduce fuel, labour and dust and emissions.
 
EMERGENCY BACK UP SYSTEM FOR YOUR STACKER/RECLAIMER
As there as so many existing stockyards using large stacker/ reclaiming systems, the Telestack equipment can also be used as an emergency back up to this equipment. In the event of a failure or planned maintenance of the stacker/reclaimer Telestack equipment can be used to maintain the production rates either
stockpiling or reclaiming the material. This is also beneficial as the units can be utilized to service the small areas in the stockyard that the stacker/reclaimer cannot reach, the mobile Telestack equipment can ‘pick up’ this material and reclaim it back into the system reducing the need for wheel loaders and trucks on site.
 
THE TELESTACK SYSTEM:THE COMPLETE PACKAGE FOR STOCKPILING / RECLAIMING IN YOUR STOCKYARD
The mobility and flexibility of the Telestack range of equipment offers the operator the complete package for stockpiling or reclaiming in the stockyard, while greatly reducing operating
costs per tonne in comparison to a stacker/reclaimer system.
The main advantage of this equipment is the multiple functionality and quick installation time that it offers, limiting capital equipment expenditure. This is a critical point, especially in the initial ‘start up’ phase of a stockyard management system, while still having the option to upgrade and incorporate multiple systems as production increases in the future.
 
 
Sandvik solutions invaluable in today’s bulk handling stockyard
Sandvik Mining and Construction is a business area within the Sandvik Group and a leading global supplier of equipment, cemented-carbide tools, service and technical solutions for the excavation and sizing of rock and minerals in the mining and construction industries. Annual sales in 2010 amounted to about SEK 35,200 million, with approximately 15,500 employees.
Wherever bulk material is handled, Sandvik Mining and Construction will be present. In addition to meeting the needs of the mining industry, the company also provides solutions for downstream operations, such as power plants and mills, ports and terminals with an approach tailored for each application.
Reclamation, stockyard storing, sizing, homogenization and transportation are all materials handling processes Sandvik supports. Sandvik offers a range of solutions for turnkey projects, individual new equipment or upgrades and modernizations, which includes consulting, systems design, engineering, procurement, erection and support. Sandvik applies materials handling and automation technologies to help customers best utilize their assets. Additionally Sandvik designs and manufactures a full range of conveyor components like idlers, pulleys, belt cleaners, etc. used in materials handling equipment, whether for new systems or replacement parts for any existing system. The goal is to make the customers more successful through long-term co-operation and partnerships; success comes from efficient process design, innovative engineering and a dedication to reliability. Through the well- developed Sandvik Mining and Construction organization, global parts logistics and local services keep the continuous materials handling processes running.
 
NEWS FROM SANDVIK
Sandvik Mining and Construction signs project order in Latin America Sandvik Mining and Construction has signed a major materials handling contract with a major mining company in Latin America.
The contract value exceeds SEK 1,200 million and will be executed and contribute to SMC business during the years 2011 until 2013. The start of the operation is scheduled for 2013.
The order includes design and supply of a long distance belt conveyor system, for downhill transportation, with designed capacity of 19,200tph (metric tonnes per hour).
“The importance and complexity of the system and the impressive performance data demonstrate Sandvik Mining and Construction's capability to provide high-tech solutions in the area of bulk materials handling systems for mining applications,” says Lars Josefsson, President of the Sandvik Mining and Construction business area.
 
COMPLETE MATERIALS HANDLING SYSTEMS
Sandvik Mining and Construction’s Materials Handling business offers all services related to bulk materials handling, including feasibility studies, conceptual plant layouts, design, engineering, and the entire execution of complete systems to handle coal, ore, bauxite and other different materials — a vast range of equipment for applications such as the following:
  • conveying, stacking, reclaiming and blending of bulk materials;
  • loading bulk materials into ships;
  • unloading bulk materials from ships; and
  • crushing, sizing and feeding of bulk materials.

This offering supports the continuous transfer of the material in various fields of materials handling solutions, whether as individual machines or as complete turnkey installations. The classical application of these systems and machines relates to stockyard facilities at mines, at export and import ports and in stockyards of power stations, steel works and processing plants.According to the requirements of the downstream consumer, Sandvik’s systems can reach output rates up to more than 10,000tph (tonnes per hour).
 
COMPLETE HANDLING SYSTEMS FOR STOCKYARDS
Stockyards, either as a circular or longitudinal layout incorporating particularly feed conveyors, stackers and reclaimers, have a central function in the fields of materials handling as they serve as material buffers, reserve or blended storage between incoming and outgoing materials. As buffering, composing and homogenizing performed by a stockyard can vary, quantity as well as quality fluctuations can be balanced out with the correctly chosen system. As the priorities for each application and stockyard operations are different, it is necessary to consider various questions before selecting type and size: throughput required, characteristics of the materials to be handled, homogenizing effect required, open or roofed storage and importantly, the future upgrading of the storage. Sandvik offers a complete range of products to provide customized solutions for each customer’s specific requirements. The equipment comprises:
  • reclaiming technology for bucketwheel boom-type, bucketwheel bridge-type, scraper-type, drum-type units;
  • stacking technology for the most commonly used stacking methods: chevron, windrow and coneshell
  • combined stacking/reclaiming technology for bucket wheel- or circular units
  • conveying technology including transfer stations
  • auxiliary equipment with hoppers, feeders, crushers, etc.
Covered storage is used where environmental aspects require the full enclosure of the stockpiles and stacking and reclaiming activities. It can either be arranged in the form of a longitudinal/rectangular configuration or in a circular configuration covered by dome-type structures.

STACKERS (PS SERIES)
Sandvik stackers effectively stockpile bulk materials in an efficient and orderly manner. Stationary or traveling, borne on rails or crawlers, they can be supplied in fixed, luffable or luffable-and- slewable boom designs, with capacities from 150 to 20 000 tonnes per hour.The choice of design depends on factors such as the stacking method 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.
 
RECLAIMERS (PR SERIES)
Sandvik reclaimers are designed to reclaim bulk materials from stockpiles at mines, ports, steel plants, power stations, etc. in a quick, efficient and orderly way (see picture on p90). They are available in several main types, including bucket wheel, scraper and drum-type reclaimers, and in many configurations and sizes, with capacities from 500tph to 20,000tph and more. The choice of design depends on factors such as the size and shape of the stockpile, the type of material to be reclaimed, the required reclaiming rate and the need for blending or homogenization.
 
STACKER/RECLAIMERS (PD SERIES)
Sandvik stacker/reclaimers come in two main types: bucket- wheel models for alternate stacking and reclaiming, and circular units, which normally stack and reclaim the material alternately but can be designed to do so simultaneously if required. The bucketwheel models, normally supplied complete with tripper cars, are compact and economical for longitudinal stockyards
where simultaneity is not required and where there can be large variations in the demand for stacking and reclaiming capacity. Standard circular units, which build a ring-shaped stockpile and are normally housed inside a covered dome because of environmental aspects, both continually stack the stockpile at one end of the ring and reclaim the material simultaneously from the other end.
 
TRANSPORTATION SYSTEMS (PC SERIES)
Sandvik has a highly skilled projects division specializing in the design, manufacture, installation and commissioning of conveyor systems for a full range of applications. Sandvik also upgrades and modernizes systems and supplies a comprehensive range of its own quality components and spare parts.