Application of Radial Stackers in Coal Mine Bulk Material Conveyance Solutions
Time:2025-08-29 10:51:20Number of Clicks:
In the coal mine bulk material conveyance chain, the stockpiling of materials such as raw coal, cleaned coal, and gangue often faces issues including insufficient space utilization in coal mining sites or coal washing plants; easy segregation (stratification of large coal lumps and coal powder) due to uneven material distribution during raw coal stockpiling, which affects the quality of subsequent washing or outward transportation; and accelerated equipment wear caused by the dusty and humid operating environment of coal mines, which impacts the continuous production of coal mines. Relying on radial stackers (ZR-SF Series) as the core, combined with long-distance belt conveyors, truck unloaders, and independently developed components such as high-wear-resistant idlers and anti-corrosion rollers, Zoomry Heavy Industry creates customized solutions featuring "efficient stockpiling + anti-segregation + weather resistance and durability" for coal mine bulk material conveyance.
Core Features of the Solution
Compared with conventional stockpiling equipment in the industry, all equipment and components of Zoomry's ZR-SF Series Radial Stackers have passed the ISO 9001 Quality Management System, ISO 14001 Environmental Management System, as well as certifications including CE (Europe), EAC (Russia), and KCS (South Korea), making them fully adaptable to the harsh operating environment of coal mines:
Flexibility and Efficiency: Radial stackers are equipped with three core adjustment functions — radial rotation (360° stepless adjustment), boom telescoping (maximum telescoping length of 20m), and luffing adjustment (-15° to +25°), which allow flexible adjustment of the stockpiling range according to the size of the coal mine site. Through the optimized "windrow material distribution" design, the stockpiling capacity is increased by over 28% compared with traditional fixed-length conveyors. Taking kaolin (with a repose angle of 45°) commonly used in coal mines as an example, a 50m-long radial stacker can achieve a stockpiling capacity of 101,275 tons, far exceeding the 65,885 tons of traditional equipment of the same specification, significantly improving the space utilization of coal mine stockyards;
Anti-Segregation Protection: Aiming at the pain point of easy stratification during raw coal stockpiling, radial stackers use a PLC automatic control system to precisely control the boom movement speed and material distribution angle, ensuring that raw coal evenly covers the surface of the stockpile and avoiding the segregation issue where large coal lumps concentrate at the bottom and coal powder floats at the top. At the same time, a buffer chute is installed at the equipment's discharge port. By reducing the material falling speed (from the traditional 3m/s to 1.2m/s), the breakage loss of raw coal is reduced, and the material integrity is improved to over 98%, ensuring the stable coal quality for subsequent washing or outward transportation;
Low-Maintenance Design: The dusty and humid environment of coal mines has high requirements for equipment sealing and wear resistance. The core components of Zoomry's radial stackers have undergone special treatments — independently produced idlers are made of HDPE material with an IP65 protection rating, and their water ingress in the 72-hour immersion test is ≤ 100g (better than China's GB standard of 150g), which can effectively block the intrusion of coal mine dust and moisture, with a service life exceeding 50,000 hours; rollers are made of 40Cr forged material, with anti-corrosion coating on the surface, and undergo ultrasonic flaw detection and stress tempering treatment. Their load-bearing capacity is 25% higher than that of ordinary rollers, enabling them to withstand the high impact load of raw coal (density 2.8-3.5t/m³); the machine frame is made of high-carbon steel with anti-corrosion coating, and its rust resistance in the humid coal mine environment is 3 times higher than that of ordinary equipment. The annual maintenance frequency of the equipment is reduced from 12 times (traditional) to 5 times.
Segmented Scenario Solutions for Radial Stackers in Coal Mine Bulk Material Conveyance
Focusing on three core scenarios of coal mine bulk material conveyance — "raw coal stockpiling in mining sites, cleaned coal stockpiling in coal washing plants, and stockpiling of coal mine by-products for transfer" — and combining the material characteristics of each scenario (such as high impact of raw coal, dust prevention requirement for cleaned coal, and high wear of gangue), Zoomry Heavy Industry develops targeted solutions with radial stackers as the core, ensuring seamless connection between the stockpiling link and the coal mine production rhythm:
Coal mining sites need to transport raw coal (particle size ≤ 500mm, containing a small amount of gangue) mined underground to the ground stockyard via long-distance conveyance for centralized stockpiling. They need to meet the demand for "large-flow continuous conveyance + rapid stockpiling" to avoid raw coal backlog in the mining site affecting underground mining. The solution centers on "long-distance belt conveyor + ZR-SF radial stacker":
Equipment Collaboration Configuration: Select long-distance belt conveyors (belt width 1400-2000mm, conveying speed 2.5-3.0m/s, conveying capacity 1000-2000tph) to transfer underground raw coal from the mine shaft to the stockyard. The machine body is treated with anti-corrosion coating to adapt to the dusty and humid environment of the mining site; match with ZR-SF Series radial stackers (boom length 15-30m optional according to the stockyard size). Through the linkage between the PLC automatic control system and the belt conveyor, seamless connection of "conveyance-stockpiling" is realized without manual adjustment of the stockpiling position;
Component Configuration: A polyurethane (PU) cleaning scraper is installed at the head of the belt conveyor, combined with a brush device at the tail, achieving a cleaning efficiency of over 98% to remove raw coal adhering to the conveyor belt surface and prevent coal slime from entering the radial stacker and causing clogging; the boom of the radial stacker adopts a lattice frame design, which is lightweight yet strong in load-bearing, enabling stable operation in mining site areas with a slope ≤ 18° without complex site leveling;
Solution Features: When applied in coal mining sites, this solution can realize 24-hour continuous operation. The raw coal stockpiling efficiency is 30% higher than that of traditional equipment, the space utilization of the stockyard is increased by 28%, and the monthly equipment downtime is controlled within 2 hours. It effectively avoids raw coal backlog in the mining site and ensures the continuous progress of underground mining.
Coal washing plants need to seal and stockpile sorted cleaned coal (particle size 0.5-5mm, moisture content 10%-15%) to prevent dust diffusion and environmental pollution. At the same time, they need to avoid moisture absorption, caking, or breakage of cleaned coal during stockpiling to ensure the quality of cleaned coal for outward transportation. The solution centers on "pipe belt conveyor + ZR-SF radial stacker":
Equipment Collaboration Configuration: Adopt pipe belt conveyors (belt width 1000-1400mm, conveying capacity 500-1000tph) to transfer cleaned coal from the washing workshop to the stockpiling area. The conveyor belt is folded into a tubular structure by 6 sets of idlers, realizing 100% sealed conveyance of cleaned coal. A non-powered dust-collecting chute is installed at the discharge end, controlling the dust concentration in the operation area below 5mg/m³ and complying with coal mine environmental standards; match with ZR-SF radial stackers, and through the "low-speed material distribution" mode (boom movement speed 0.5-1m/min), cleaned coal is evenly stockpiled to avoid caking caused by excessive local pressure;
Component Configuration: The inner wall of the hopper of the radial stacker is lined with polytetrafluoroethylene (PTFE) liners to reduce the adhesion rate of cleaned coal. At the same time, a vibration device is equipped at the bottom of the hopper to prevent clogging of moist cleaned coal; a rain cover is installed on the top of the stacker to prevent rainwater from entering the stockpile and causing moisture absorption of cleaned coal, ensuring that the moisture content of cleaned coal is stably controlled within 15%;
Solution Advantages: This solution can reduce the stockpiling loss rate of cleaned coal from 5% (traditional equipment) to 1.2%, reduce the dust pollution rate to below 0.3%, and control the caking rate of cleaned coal within 2%, fully meeting the dual requirements of coal washing plants for cleaned coal quality and environmental protection. At the same time, the stockpiling efficiency is increased by 25%, shortening the waiting time for cleaned coal outward transportation.
Efficient Disposal Solution for Gangue/Middlings with Radial Stackers
Gangue (high hardness, high density) and middlings (used for power generation in self-owned power plants) generated during coal mine production need to be separately stockpiled and disposed of. Such materials have extremely high requirements for equipment wear resistance, and need to be quickly stockpiled to avoid occupying production sites. The solution centers on "truck unloader + ZR-SF radial stacker":
Equipment Collaboration Configuration: Adopt ZRLS-TU Series Truck Unloaders (belt width 1400-1800mm, conveying capacity 600-1800tph, wheeled or tracked optional) to receive gangue/middlings from transfer trucks. Equipped with 2-4 lane unloading ramps, it supports simultaneous unloading of multiple trucks to avoid vehicle queuing and congestion; transfer materials to ZR-SF radial stackers (reinforced booms selected, with load-bearing capacity 20% higher than that of conventional models) via short-distance belt conveyors to realize rapid stockpiling;
Component Configuration: The inner wall of the chute of the radial stacker is lined with 15mm-thick wear-resistant alloy liners to resist the high impact wear of gangue, extending the service life to over 8 years; the traveling system of the stacker adopts extra-solid tires (8 tires, load-bearing capacity 10t each) or a tracked design, which can stably move on the soft ground of the coal mine by-product stockpiling area without additional hardening of the road surface;
Solution Advantages: This solution can increase the stockpiling efficiency of gangue/middlings by 40% compared with traditional equipment, extend the service life of wear-resistant components of the equipment by 3 times, and reduce annual maintenance costs by 35%. At the same time, it realizes rapid disposal of coal mine by-products, avoids occupying production sites, and ensures the smooth progress of the main coal mine production process.
Zoomry Heavy Industry's Service Support
In view of the undulating slopes of coal mining sites and the compact space of coal washing plants, the parameters of radial stackers are pre-adjusted before leaving the factory based on the site CAD drawings provided by customers — for example, the track tension of stackers used in mining sites is optimized in advance to adapt to soft ground, and the boom rotation radius of stackers used in coal washing plants is pre-shortened to avoid equipment obstacles; during the on-site installation phase, engineers with more than 5 years of coal mine equipment service experience are dispatched to station on-site, solving problems throughout the whole process of "equipment installation - connection with existing conveying systems - no-load commissioning" simultaneously. It ensures that the time from equipment arrival to commissioning is only 10-15 days, which is 30% shorter than the industry average cycle;
Zoomry Heavy Industry provides regular inspection services for core wearing parts of radial stackers (such as wear-resistant liners, hydraulic winches, and sealed idlers) — inspecting the boom structure stress on-site every 3 months and replacing the hydraulic system filter element every 6 months to avoid chain failures caused by component wear; "coal mine emergency spare parts warehouses" are established in major global coal-producing areas (such as Queensland, Australia; Zambia, Africa; Shanxi, China). Special spare parts for radial stackers (such as boom telescopic cylinders, PU cleaning scrapers) can be delivered to the coal mine within 24 hours, and the emergency response time for sudden failures does not exceed 4 hours, minimizing the loss caused by a single downtime;
Provide "practical operation courses for radial stackers in coal mine scenarios", such as how to judge hopper clogging through remote monitoring in dusty weather, the method of adjusting hydraulic system pressure in humid environments; the manual unlocking process for sudden boom jamming, the 5-minute quick adjustment plan for conveyor belt deviation; the regular inspection cycle for idler seals, and the touch-up process for roller anti-corrosion coating. The training adopts the "theory + on-site practical operation in underground/mining sites" mode to ensure that each operator can independently complete daily maintenance and simple fault troubleshooting, reducing the rate of human operation errors;
Control costs from the dual dimensions of "equipment maintenance + site utilization": The high-wear-resistant design of radial stackers (such as 15mm alloy liners for chutes, IP65 sealed idlers) enables the service life of core components to exceed 50,000 hours, reducing the replacement frequency by 60% compared with traditional stackers and lowering annual maintenance costs by 35%; at the same time, the stockpiling capacity is increased by 28%, which can reduce the investment in coal mine stockyard expansion. For a coal mine with an annual output of 1 million tons, the cost saved only from site can reach more than 2 million yuan per year;
Eliminate the connection bottleneck of "conveyance - stockpiling - outward transportation": Through the linkage control between radial stackers and long-distance belt conveyors, seamless connection of raw coal "underground mining - ground conveyance - stockpile storage" is realized, and the stockpiling efficiency is increased by 30%, avoiding the shutdown of underground mining caused by raw coal backlog in the mining site; for the cleaned coal outward transportation scenario, the anti-segregation design of stackers improves the homogeneity rate of cleaned coal to 98%, enabling direct loading without secondary screening and shortening the outward transportation preparation time by 40%;
Improve coal quality and environmental compliance: There is no dust leakage (dust concentration ≤ 5mg/m³) or caking (caking rate ≤ 2%) during cleaned coal stockpiling, significantly improving coal quality stability, which can help coal mines obtain a 5%-8% premium in the sales link; at the same time, the equipment complies with environmental certifications such as EU CE and Russia EAC, helping coal mines meet the export requirements of overseas markets and expand sales channels.
