Mobile Stacker Reclaimer for Ultimate Stockyard Management

// 12 May 2021 @ 13:27

Telestack's Mobile Stacker Reclaimer systems 

improve efficiency and provide operators with the

ultimate flexibility in their stockyard

Telestack specialises in the design, manufacture and installation of a complete range of mobile stockyard management solutions for handling a complete range of dry bulk materials. The Telestack mobile range of equipment takes into consideration the ‘day to day operational capabilities and ‘bottle-necks’ of any stockyard system, consisting of Stockpiling, Reclaiming, Blending, Truck Unloading and material transport. The Telestack equipment offers the operator cost-efficient solutions with unrivalled mobility and flexibility.

    • Do you want to improve efficiencies in your stockyard?
    • Do you want to lower your cost per tonne?
    • Do you want to efficiently transfer your coal from differing yards (Inter-yard transfer)?
    • Do you want the ability to blend your coal?
    • Do you want a backup system for your primary bucket wheel stacker reclaimer?
    • Do you want to expand your current stockyard with minimal investment and a short time frame?

These are all the critical factors for any stockyard operation and the Telestack mobile stockyard range offers reliable, flexible and robust solutions to achieve all of these objectives.

Telestack's mobile stacking and reclaiming benefits include:

    • Increase efficiency in your stockyard
    • Significantly Lower Capex investment
    • Lower operational costs
    • Reduced maintenance and downtime
    • Utilise previously unused space
    • Improved flexibility in operations
    • Equipment easily transported to other sites
    • Maintain high throughput rates
    • Equipment maintains resale value
    • Offers back-up solution during stacker-reclaimer downtime

Why use a Mobile Stacker for your stockyard management

Links feeding onto Radial Telescopic Stacking in Russia

Telestack’s radial telescopic conveyor is one of the most cost-efficient and effective ways of stockpiling material on the market and can stockpile coal, for example, at up to 2,000tph, with stockpile heights of up to 20 metres and a stockpile capacity greater than 100,000 tonnes. The radial, telescopic and luffing (up / down) facility of the units allows the operator to utilise the entire space, even in areas with restricted stockpile height. In addition, the automatic PLC stockpiling system reduces the labour required to operate the equipment, whilst reducing the degradation, segregation, contamination and compaction of the coal. The robust heavy-duty design allows stockpiles of up to 2,000tph with the ability to handle a complete range of materials from coal / pet coke to iron ore which is ideal for multi-material stockyards.

The mobility of the units is key to ensure production rates are maintained changing from one stockpile to another. Telestack’s integrated tracked dolly units ensure a highly mobile independent unit with the ability to operate with ease on harsh ground conditions within the stockyard. 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 / Inter-yard transfer to maximise the space/efficiency in the yard as required while limiting downtime in the stacking process.

Reclaiming: Utilising the Telestack equipment for your stacking and reclaiming

The Telestack equipment is ideally suited for both the stacking and reclaiming processes. The multi-functionality of the equipment ensures capital expenditure is kept to a minimum but high production capacities are maintained. The mobility of the units allows the change over 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 utilised to limit the haulage dist

These link conveyors can then feed directly onto the overland conveyor system. The mobile reclaim hopper can also be used to feed directly onto the overland conveyor system (if required), which eliminates the double handling of the material. The mobile truck unloader can also be fed directly from trucks in the stockyard to feed the stacking reclaiming line, again to increase production capacities during the reclaiming process. The mobile reclaims hopper, truck unloaders and link conveyors, used in the stockpiling process give the operator the complete package for an efficient stockyard system.

A proven method of Coal Blending by Telestack

The blending of coal in stockyards is one of the most important processes for feeding power plants and other facilities. An example, Telestack has recently installed a proven system involving the accurate blending of differing grades/ qualities of coal within a Power plant in South East Asia. In any given Power plant stockyard there will be various grades and specifications of coal which will have been sourced from various countries in various batch sizes. Each of these grades will have a differing value of the following main material characteristics.

  1. Calorific Value
  2. Ash Content
  3. Sulphur Content
  4. Moisture Content

The challenge for any power plant operations team is how to accurately blend the various grades of coal with the above varying material characteristics to ensure that they are sending a consistent blend to the furnace.

Traditionally this blending had been carried out by using 2 x bucket wheel Stacker Reclaimers which fed onto a central conveyor which then sent the blended coal mix to the furnace. The main issues with this method of blending are that the blend ratios can vary dramatically and as such one of the Stackers Reclaimers may be operating at a greatly under-utilized rate.

This results in high operating costs per tonne for the process of reclaiming at these lower rates. For example, a power plant may want to blend coal of lower calorific value with that of a higher calorific value. The total reclaim rate to the furnace is 1,400tph. If using an 80% higher grade coal to 20% lower grade blend, then the Stacker Reclaimer A is operating at 1,120tph while the Stacker Reclaimer B is only operating at 280tph. The operating costs per ton for Stacker Reclaimer B, as a result, are excessive.

Truck Unloading

The design of many Power Plant stockyards allows for both stacking of imported coal whilst unloading vessels and simultaneous reclaiming of coal from the beds to the furnace. However, when unloading vessels and stacking, a typical layout would incorporate 2 x ship unloaders and these would feed material to 2 x stackers. This normally only leaves 1 x Stacker Reclaimer to send material to the furnace and as such blending cannot be carried out when unloading vessels. If reclaiming sub-bituminous coal can result in the de-rating of power generation. This can also occur during periods when carrying out repair and maintenance on the Stacker Reclaimer when the unit is not in operation. This can put additional pressure on other reclaimers when carrying out normal day to day reclaiming/stacking duties. Having worked closely with several operations teams within power plants, Telestack listened to the issues facing them and have worked in conjunction with them to offer a unique and innovative technical solution to the above operational issues.


The equipment selected was a Telestack Mobile Track Mounted Titan Truck Unloader with integrated Hopper Feeder with Radial & Luffing Boom. The machine was selected because of its excellent mobility and manoeuvrability around the narrow areas of the stockyard and narrow access roads between the stockpile and the reclaim line. The radial boom enabled the machine to fit within the 5 metre area and reach the reclaim line. The fully self-contained machine with Cat 96kw diesel engine and 4.1 metre crawler tracks allows the unit to travel over rough terrain especially in the rainy season when heavy rutting can occur on access roadways.

Improving Cycle Times and Efficiency in your stockyard

The Telestack solution has a fully integrated feed hopper to allow the trucks/ wheel loader to ‘dump’ and go, thus improving the cycles times and efficiency as well as allowing better control of the material onto the incline section. The integrated hopper is specially designed using a chain apron belt feeder which combines the strength of an apron feeder along with the sealing quality of a belt feeder. The Telestack design ensures versatility in that it can be fed by a front end loader/ excavator or trucks. When reclaiming the machine is fed by one, or a combination of the above, and can be set at pre-set percentage ratios with the touch of a button. The Telestack radial Titan can work in conjunction with a Stacker Reclaimer to send an accurate blend to the furnace. The unit incorporates a dual idler belt-weigher which is connected to a PLC on the machine; this PLC controls the feed rate to the reclaim line and can be linked to the central control room via an Ethernet connection or a Wi-Fi communication system.

Improve cycle times in your stockyard


Rail Wagon Loading

A recent installation in Western Australia used a Telestack HF 24 tracked mobile hopper feeder in a Train Loadout application to increase the loading rates and operate the TLO more efficiently. The TLO in this particular application had a significantly higher capacity than the Ore Processing Facility (OPF) and in order to operate the TLO efficiently, a further 2,000tph of material was required. The HF 24T, fed simultaneously by 2 x CAT 992 loaders discharged onto the TLO conveyor circuit thus increasing the loading rates significantly.

The HF 24T Mobile Hopper Feeder is fully mobile meaning that it can easily and quickly be relocated along a fixed conveyor in the stockyard to reduce loader tramming distance. With a hopper capacity of 24m³ (50-60T of Iron Ore), the Customer is now able to operate the TLO at full capacity, reducing the loading time required on site. This reduced the time taken to get the iron ore from pit to port, has improved the rail cycle time and increased the potential capacity of the operation. Due to the ease of road transport and on-site mobility, the Telestack HF 24T can also be used as an emergency backup for other equipment across the company’s mine and port operations.

Moreover, the ability to transport the Telestack HF 24T on a standard 75T trailer under its own power with no cranes, with standard road permits, no police escorts and no power line lifts, means that this unit is ideal for a multi-site operation. When on-site it can be tracked into position and folded out under its own power with no tools or cranes required. When in position it can be connected to an electrical power source with the attached cable/ plug and can be operational within a very short period of time. This makes the Telestack HF 24T an ideal permanent or mobile emergency feeder to use in the case of planned or unplanned maintenance across your multiple mining operations, stockyard, port or bulk material handling operation. Telestack offers a range of reclaim feeders from 300tph – 3000tph.

 Hopper Feeder RangeEmergency Back-up System for your Stacker Reclaimer

In the event of a failure, planned maintenance, high winds on-site or if the stacker reclaimer is shut down, Telestack equipment can be used as an emergency backup system due to the mobility and ease of use. In this instance the Telestack equipment can be used to maintain the production rates for either blending, stacking or reclaiming the material. This is also beneficial as the Telestack equipment can be utilised to service small areas of the stockyard that the stacker reclaimer could never reach. Safety on site also improves as the mobile Telestack equipment can ’pick up' material and reclaim it back into the system reducing the need for wheel loaders and trucks on site.

Changing trends: A mobile alternative to the bucket wheel stacker reclaimer

Traditionally bucket wheel stacker reclaimers have been typically used in developing a greenfield site or when upgrading a current stockyard and there are many manufacturers of stacking and reclaiming systems worldwide with varying associated capital costs depending on the operational requirements. The substantial costs associated with this type of traditional installation includes civil requirements, planning permission and government legislation etc. These factors further increase the capital expenditure and time frame of the project.

As technology progresses worldwide, times and traditions are changing and more and more operators are turning to Telestack innovative mobile solutions as a cost-efficient alternative.

Telestack equipment is designed for operators handling up to 5,000,000t per year with a single system, 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 their capital expenditure. For those developing new Greenfield sites, the Telestack equipment is perfect for the initial ‘start-up phase’ of the project as there are lower capital costs, no civil requirements/limited planning permission and a short lead time (3 – 6 months) The operator can very quickly begin phase one of the stockyard and generate revenue.

The Telestack System: The complete package for Stacking, Reclaiming and Blending in your stockyard

The mobility and flexibility of the Telestack range of equipment offer the operator a complete package for stacking or reclaiming in the stockyard, while greatly reducing operating costs per tonne in comparison to a traditional bucket wheel stacker reclaimer system. Telestack has many proven stacker and reclaimer installations globally and continues to innovate to meet the ever-changing needs of their customers.