Environmental News

Overcoming stockpile limitations in mobile operations

While tracks have given them mobility and flexibility, the limited stockpile capacities of on-board conveyors have provided new challenges for crushing and screening operations.

The traditional method of using a wheel loader to remove the finished product and build the main stockpile has its drawbacks, namely fuel consumption, labour costs and safety issues of driving up/down stockpiles, which can contaminate the finished product.
Suppliers such as Telestack Limited offer a complete range of crawler track-mounted mobile conveying solutions to overcome these drawbacks.
Using a tracked conveyor can allow discharge heights of up to 11 metres and stockpile capacities up to 11,000 tonnes from one single position. This reduces fuel consumption by up to 80 per cent compared to wheel loaders, as well as eliminating the need for a driver. As a result, operating costs (fuel, labour, maintenance) are significantly lowered. See Charts 1 and 2 (page 36) for a cost comparison of a Telestack tracked conveyor versus wheel loader.
Site safety is also greatly improved, as there are less traffic movements and the wheel loader no longer has to drive up and down the stockpile to ensure the capacities are maintained. Environmental benefits include less dust, noise and exhaust emissions.
Telestack?s tracked mobile range allows operators to build conical or radial stockpiles up to 11,000 tonnes before the crushing and screening equipment needs to be moved, ensuring operators benefit from the maximum flexibility and efficiency of a mobile crushing and screening plant. 
The Telestack range can cater for all applications from light duty screening to heavy-duty crushing up to 250mm at 600 tonnes per hour. The range has lengths from 20m up to 24m tracked and radial options, depending on the client-specific application. Also, the new automatic stockpiling program for the TC Radial range, allows for automatic stockpiling on-site, reducing material degradation, compaction, contamination and enables a ?single man? operation for the entire crushing and screening operation. The Programmable Logic Controller options include TC 421R ?Auto Arc? stockpiling and ?conical incremental?, depending on client needs.

REDUCING DOUBLE  HANDLING OF MATERIAL
The ability to reduce and eliminate the double handling of material is key to reducing costs per tonne. Whether feeding from trucks, wheel loaders, excavators or grabs, Telestack?s range of mobile truck unloaders offer the operational mobility and flexibility required for an efficient process on-site.

Telestack?s range of truck unloaders are extensive, taking into consideration varying truck sizes, payloads, materials, cycle times, unloading rates, etc, all customised to the needs of the client and operation. As with all Telestack products, the mobility and flexibility of the units are the key features.
The tracked mounted option gives the operator unrivalled flexibility when moving around the site, as this unit is completely independent of all other systems. There is a diesel engine to drive all functions, with an optional dual power upgrade available; this means the unit can be tracked into position and plugged into the three-phase electrical supply to power the conveyor belts. This limits the diesel consumption of the units. There is also an option of rubber track pads that ensures the concrete/asphalt surfaces are not damaged from the tracks. The greater mobility of these units also ensures they can be used in other applications within mines, ports and stockyards, power stations and many more, important for possible re-sale value if contracts are finished. There are also wheeled options available for a more basic unit that allows the operator to tow the unit around the site into each position. Telestack can also offer a static version, depending on the specific needs of the client.
Typically, the range of truck unloaders can handle trucks up to a 70-tonne payload (tipping or dump truck); the large hopper capacity increases cycle times which increases production rates. As there are such a wide range of trucks available in the market, Telestack can customise design the hopper area to facilitate the most effective and efficient unloading area, including extended hopper sides, folding sides, flared design, dual access (increased cycle times), integrated fall break and many more. This ensures that the flow rate of each specific material and truck can be defined and taken into consideration during the design procedure, taking into account differing materials, high capacity feeding methods and production rates. Also, the unloaders can be easily fed from wheel loaders and grab cranes for added flexibility. When handling dry bulk material, the dust suppression measures installed on the units ensure minimal dust emissions when unloading.

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All truck unloaders incorporate a heavy-duty apron chain belt feeder, which ensures the surge of material discharging from the truck can be transferred and controlled onto the incline conveyor or auxiliary equipment. Unlike other feeder conveyors that use rollers which would slip under the intense load in the hopper, the chain and sprocket driven belt ensures there is no slippage and stalling of the feeder conveyor. The ease of site to site transport allows for further flexibility to cater for a range of industries and an ideal contractor?s unit for cheaper transport costs than fixed conveyor systems.

Source: The Lincom Group

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