Stacker Reclaimer for Coal, Ore and Port Stockyards: Selection Guide

A stacker reclaimer is the machine that both builds and recovers stockpiles in a bulk material stockyard. In coal, ore and port stockyards, the same machine stacks material into piles and reclaims it for ship loading, rail loading or processing. The selection of a stacker reclaimer is therefore driven by the stockyard layout, the material, the throughput and the downstream process — not by the machine alone.

This article sets out the selection criteria for stacker reclaimers in coal, ore and port stockyards, compares the main configurations, and provides the parameters that determine the final specification.

1. What a stacker reclaimer does in a stockyard

A stacker reclaimer combines two functions in one machine:

• Stacking — a boom conveyor discharges material onto the stockpile at a controlled rate and position, building the pile in layers.
• Reclaiming — a bucket wheel or bucket chain cuts material from the pile face and discharges it onto the yard conveyor, which transfers it to the downstream process.

The machine travels along the stockyard on rails, on tracks, or is fixed at a single point. The choice of travel system, boom length and reclaiming device determines how the stockyard is operated.

For a definition of the machine, see What is a bucket wheel stacker reclaimer? For the stacker types used in stockyards, see Stackers for Bulk Material Stockyards: Types, Selection and Applications.

2. Three stockyard types and what they need

2.1 Coal stockyards

Coal stockyards at power plants and coal terminals require a stacker reclaimer that can handle high throughput, control dust and manage the risk of spontaneous combustion. The machine must be able to build and reclaim piles without leaving dead zones, and the stockyard layout must allow the pile to be turned over on a defined interval.

Typical requirements: capacity from 1,000 to 3,500 t/h, boom length 40–60 m, dust suppression at the transfer points, and fire detection and suppression on the machine and in the stockyard.

2.2 Ore stockyards

Iron ore, copper ore and bauxite stockyards require a stacker reclaimer that can handle abrasive material and high bulk density. Bucket wheel teeth and the bucket wheel structure wear faster in ore than in coal, and the machine must be designed for the maintenance interval the operation can support.

Typical requirements: capacity from 1,500 to 4,000 t/h, heavy-duty bucket wheel and wear liners, and a structural design that accounts for the higher bulk density of ore.

2.3 Port stockyards

Port stockyards serve ship loaders and receive material from truck unloaders, rail wagons or incoming conveyors. The stacker reclaimer must be able to build piles in a layout that allows the ship loader to reclaim efficiently, and the machine must be able to handle multiple grades of material without cross-contamination.

Typical requirements: capacity from 1,000 to 3,500 t/h, multiple pile positions, and a control system that integrates with the ship loader and the terminal management system.

3. Configuration selection

3.1 Rail-mounted, tracked or fixed

Configuration	Best for	Limitations
Rail-mounted	Long, linear stockyards with fixed rail lines; high throughput; multiple pile positions	Requires rail infrastructure; limited to the rail line
Tracked	Stockyards where the machine must move between piles on unprepared ground; changing layout	Lower travel speed; higher ground pressure than rail
Fixed	Single-pile applications; radial stockyards; low throughput	Cannot serve multiple piles without a transfer system

3.2 Boom length and wheel diameter

The boom length determines the reach of the machine and the height of the pile it can build. The wheel diameter determines the cutting depth and the reclaiming rate. Both must be matched to the stockyard geometry and the material.

3.3 Bucket wheel or bucket chain

Bucket wheel reclaimers are the standard for coal, ore and port stockyards. Bucket chain reclaimers are used in some applications where the material is difficult to handle with a wheel, but they are less common in high-throughput stockyards.

ZOOMRY's BW-SR series is the stacker-reclaimer configuration for coal, ore and port stockyards. The BW-R series is the dedicated reclaimer for stockyards where stacking is handled by a separate machine. For the dedicated reclaimer, see BW-R Bucket Wheel Reclaimer. For the combined machine, see BW-SR Bucket Wheel Stacker Reclaimer.

4. Capacity and throughput

The capacity of a stacker reclaimer is determined by the boom conveyor width, the bucket wheel size, the material and the stockyard layout. ZOOMRY configurations cover the range required by coal, ore and port stockyards, with custom configurations for higher throughput.

The stacking and reclaiming capacities are not always the same. A machine may stack at a higher rate than it can reclaim, or vice versa. The selection must be based on the higher of the two requirements, and the downstream conveyor must be sized for the same rate.

5. Dust control and environmental requirements

Dust is generated at the stacking discharge point, at the reclaiming face and at the transfer points between the machine and the yard conveyor. Control measures include water spray, dry fog, enclosures and belt covers. The choice depends on the material, the local environmental regulations and the proximity of the stockyard to sensitive areas.

For coal stockyards, dust control is also linked to fire prevention. Coal dust accumulation on the machine and in the stockyard must be managed as part of the fire safety plan.

6. Maintenance and safety

Stacker reclaimers require regular inspection of the bucket wheel, the boom conveyor, the travel system and the slew system. Bucket teeth and wear liners are the fastest-wearing components and must be checked on a defined interval. The structural components are subject to fatigue loading and require periodic non-destructive inspection.

Safety considerations include emergency stop systems along the travel path, anti-collision systems where multiple machines share a stockyard, guards on rotating parts, and procedures for working near the pile face. For coal stockyards, fire detection and suppression systems are required on the machine and in the stockyard.

7. Selection checklist

• Stockyard type: coal, ore or port.
• Material: bulk density, particle size, moisture, abrasiveness and combustibility.
• Required stacking and reclaiming capacity (t/h).
• Number of piles and pile positions.
• Travel system: rail-mounted, tracked or fixed.
• Boom length and wheel diameter.
• Dust control and environmental requirements.
• Integration with ship loader, rail loading or processing plant.
• Maintenance access and spare parts availability.

8. FAQ