Bucket Wheel Stacker Reclaimer

The ZOOMRY Bucket Wheel Stacker Reclaimer is a core equipment specially developed for global large-scale bulk material stacking and reclaiming scenarios. As a professional bulk material stacking and reclaiming device and mobile stacker reclaimer, its rated capacity covers 500-3000 m³/h, equipped with 8-12 customized bucket wheels (diameter 5254-8200 mm), capable of efficiently completing bulk material stacking and reclaiming operations in mining, port, and other scenarios. The equipment features a crawler travel system (ground pressure 125-193 KPa) and a 360° slewing mechanism, adapting to different terrains and stockpile scales, while certified by CE and EAC international standards. In the fields of mining bucket wheel stacker reclaimers and port reclaimers, it stands out as the preferred solution for global industrial bulk material handling with “high throughput, strong stability, and broad adaptability,” and can also function independently as bucket wheel stacking equipment for large-scale bulk material storage operations.

Core Functions of the Bucket Wheel Stacker Reclaimer

As a professional equipment focused on “integrated stacking and reclaiming,” the core competitiveness of the ZOOMRY Bucket Wheel Stacker Reclaimer lies in “high throughput adaptation + stability in complex scenarios + flexibility in mobile operations”—addressing pain points in mining and ports such as “large bulk material volumes, irregular stockpile shapes, and complex site terrain” through the coordinated design of the bucket wheel system, travel mechanism, and slewing device, resolving issues with traditional bulk material equipment like “insufficient throughput, limited operational range, and poor terrain adaptability,” while meeting global customers’ dual demands for “international compliance and long-term durability.”

500-3000 m³/h Throughput Assurance

The core bucket wheel system centers on “multi-bucket collaboration + wear-resistant design,” with 8-12 bucket wheels evenly distributed circumferentially, each with a capacity of 0.25-0.71 m³, flexibly configurable based on throughput needs: for 500-1500 m³/h medium-scale bulk materials, 8-10 bucket wheels are suitable; for 1500-3000 m³/h large-scale bulk materials, 10-12 bucket wheels are selected, paired with a bucket wheel speed of 5-6 r/min for efficient grabbing. Bucket wheel blades use 16 mm thick wear-resistant manganese steel (Mn13) with tungsten carbide overlay welding on the surface, improving wear resistance by 150% over ordinary carbon steel, capable of withstanding long-term impacts from hard bulk materials like mining ore and port coal; deflector plates inside the bucket wheel guide materials quickly into the conveyor belt, preventing residue and blockages, with material residue rate ≤0.3%, reducing cleaning and maintenance time.

The bucket wheel drive system employs 75-1100 KW high-power motors, precisely matched to throughput: 500-1000 m³/h suits 75-220 KW motors, 1000-2000 m³/h suits 220-630 KW motors, 2000-3000 m³/h suits 630-1100 KW motors, with motor efficiency over 96% and protection grade IP55, resisting erosion in dusty mining and high-salt mist port environments. The drive system also includes overload protection; when the bucket wheel encounters oversized materials (e.g., ore >500 mm diameter), it automatically reduces speed and alarms, preventing motor burnout and ensuring continuous operation.

Crawler Travel and Slewing Mechanism

The crawler travel system provides flexible mobility, with drive options of “hydraulic motor + reducer” or “electric motor reducer,” travel speed 0-2 Km/h (working mode 0.51 Km/h), adjustable based on operational rhythm. Track shoe width reaches 600 mm, ground pressure controlled at 125-193 KPa—half that of traditional wheeled stacker reclaimers—evenly distributing weight on complex grounds like soft mining sites and port stacking areas, avoiding entrapment while minimizing damage to ground infrastructure.

The slewing mechanism supports ±65-360° full-angle rotation for the bucket wheel reclaiming arm and ±90-±105° adjustment for the discharge arm relative to the reclaiming arm, combined with 15 m upward digging height and 1 m downward digging height, covering an 80 m diameter operational range. A single unit can complete the full “edge reclaiming—center stacking” process for large stockpiles without frequent repositioning. Slewing drive uses dual hydraulic motor linkage, outputting torque up to 12000 N·m, ensuring smooth rotation even under full load, with slewing error ≤0.5°, precise reclaiming positioning, and reduced material spillage loss.

Wide Bandwidth Conveying System

The conveying system serves as the core link for “bucket wheel reclaiming—stacking/transfer,” with reclaiming belt width 1200-1600 mm and belt speed 2.5-5.0 m/s, flexibly matched to throughput: 500-1500 m³/h suits 1200 mm width + 2.5-3.0 m/s speed, 1500-3000 m³/h suits 1400-1600 mm width + 3.0-5.0 m/s speed. Conveyor belt material is nylon core wear-resistant rubber (14 mm thick), longitudinal tensile strength 2000 N/mm, with diamond anti-slip pattern on the surface (10 mm depth), improving anti-slip performance by 50%, preventing slippage and deviation of wet coal or sticky ore during transport; 400 mm high wear-resistant rubber skirts on both sides with internal steel wire skeleton reduce side leakage, suitable for “continuous high-load conveying” needs.

The conveying system also features an automatic tensioning device, real-time adjusting tension based on belt load (range 8-15 kN), preventing slack slippage or overtight tearing; head and tail each equipped with heavy-duty polyurethane cleaning scrapers, cleaning rate 99.5%, thoroughly removing residual bulk debris from the belt surface, reducing belt wear and extending conveyor life to over 3 years.

Core Components of the Bucket Wheel Stacker Reclaimer

The long-term stable operation of the ZOOMRY Bucket Wheel Stacker Reclaimer relies on targeted design of core components around “high load, wear resistance, easy maintenance”—from bucket wheel drive to crawler travel, each part undergoes scaled simulation testing at ZOOMRY’s quality inspection center, ensuring adaptation to continuous high-load operations in global mining and ports.

Bucket Wheel Drive and Transmission System

Beyond high-power motors, the bucket wheel drive system pairs with ZLY series hard-toothed surface reducers, transmission efficiency 97.5%, load capacity 60% higher than ordinary reducers, withstanding instantaneous impact loads during hard material grabbing (max impact torque 1.5 times rated). Elastic couplings connect reducer and bucket wheel shaft, buffering startup impacts and protecting transmission parts; equipped with torque limiters, automatically cutting power when load exceeds 120% rated, preventing drive system damage.

Bucket wheel shaft uses 42CrMo forged material (diameter ≥280 mm), quenched and tempered (hardness 220-250 HB), surface nitrided (depth 0.5 mm), fatigue strength improved 40%, enduring radial and axial loads long-term, service life over 50000 hours. Bucket wheel and shaft connection uses high-strength bolts (M36, torque 2500 N·m) with positioning pins for precise alignment, preventing radial runout during operation and ensuring reclaiming stability.

Crawler Travel and Hydraulic System

The hydraulic drive version of the crawler travel system equips 166-1410 KW total power hydraulic pump stations (matched to equipment specs), oil tank capacity 1200-2500 L, with quadruple high-precision filtration (5 μm accuracy), hydraulic oil cleanliness NAS 7 grade, reducing component wear, system annual failure rate below 0.4%. Hydraulic lines use high-pressure hoses (31.5 MPa working pressure), stainless steel joints, excellent corrosion resistance, suitable for high-salt mist ports and dusty mines.

Crawler tensioning uses hydraulic cylinder auto-tensioning, real-time adjusting based on ground hardness, preventing loose derailment on soft ground or excessive wear on hard; drive and guide wheels forged steel integral, tooth surface quenched to HRC60, wear life over 10000 hours; track shoe connecting pins use 40CrNiMoA alloy steel, phosphating treated, rust prevention improved 60%, avoiding jamming in high-humidity mining environments.

Slewing and Luffing Mechanism

Slewing mechanism adopts “dual slewing bearings + dual drive motors,” four-point contact ball bearings (diameter 3-5 m), load capacity 2000 kN, bearing axial, radial loads and overturning moments simultaneously, slewing clearance ≤0.1 mm, ensuring precision. Dual motors synchronously output via planetary reducers driving the bearing, slewing speed 0.1-0.5 r/min, precisely adjustable for reclaiming needs, avoiding over-compaction difficulties.

Luffing mechanism uses dual hydraulic cylinders for synchronous drive, controlling reclaiming arm lift, cylinder bore 180-250 mm, stroke 2-4 m, achieving 15 m upward and 1 m downward digging height adjustment. Cylinder seals imported polyurethane, oil- and wear-resistant, life over 8000 hours; luffing system with position sensors, real-time arm height feedback, precisely displayed on HMI, preventing overtravel structural damage.

Intelligent Control System

The equipment control system centers on “large-scale operation automation,” equipped with 15-inch HD HMI touchscreen, supporting English, Russian, Spanish, Chinese multilingual switching, interface focused on “stacking/reclaiming parameter settings,” storing 5 common operation programs (e.g., mining ore reclaiming, port coal stacking), one-key recall for scenario switching without re-debugging. System supports three control modes:

• PLC fully automatic mode: Laser level sensors real-time collect stockpile height and shape, automatically planning bucket wheel reclaiming paths (e.g., layered, fan-shaped), synchronously controlling crawler travel and slewing, achieving “unmanned” stacking/reclaiming, one unit replacing 3-4 operators, reducing labor costs;
• Remote control mode: 200 m industrial wireless remote, IP67 anti-interference, operators observe stockpile from safe areas, real-time adjusting bucket wheel speed, travel speed, slewing angle, avoiding close contact with bulk dust and equipment operation;
• Manual mode: Quick switch in emergencies, manual interface with “load warning,” automatically limiting throughput and alarming when exceeding safe threshold (e.g., 3300 m³/h), ensuring controllability in large-scale operations.

Modular Transportation and Efficient Installation

Addressing global mining and port project pain points of “large equipment volume, difficult cross-border transport, long installation cycles,” the ZOOMRY Bucket Wheel Stacker Reclaimer adopts “core module disassembly + high pre-assembly ratio” design, significantly reducing transport and installation difficulty while maintaining large-scale performance, ensuring rapid project commissioning.

Modular Disassembly

Equipment disassembles into 5 standard units: “bucket wheel module, reclaiming arm module, crawler chassis module, electrical control module, hydraulic module,” each sized for 40 ft high cube containers (12.03 m × 2.35 m × 2.69 m): bucket wheel module hydraulically folds to 2.5 m height, weight ≤35 t; reclaiming arm disassembles into 2-3 sections (each ≤10 m), single section ≤40 t; crawler chassis splits left/right, each ≤50 t; electrical and hydraulic modules integrated in waterproof enclosures, no special permits needed. Compared to traditional integral stacker reclaimers requiring “special transport + oversized customs,” cross-border logistics costs reduced 45%, core parts (bucket wheel, reducer) factory-packaged for rust/impact protection, adapting to Europe, Africa, Southeast Asia logistics.

High Pre-Assembly Installation

80% pre-assembly completed at factory, including bucket wheel-reclaiming arm connection, crawler chassis splicing, hydraulic line initial docking, electrical parameter calibration, plus 120-hour full-load trial (simulating 3000 m³/h large-scale stacking/reclaiming), ensuring site installation fault-free. Site requires only 4 core steps: modular unit splicing via high-strength bolts for bucket wheel-reclaiming arm and crawler left/right, 3 people 4 hours; final hydraulic/electrical plug docking with quick connectors for leak-free, ≤2 hours; slewing and luffing debugging for angle/height calibration, ≤1 hour; no-load testing and parameter fine-tuning for bucket wheel, crawler, conveying functions, skilled team completes all in 2 days.

ZOOMRY provides multilingual technical manuals with 3D installation animations and step-by-step guides, highlighting heavy equipment notes (bolt torque, hydraulic venting), plus 24-hour online support via video for global installation queries, deployable without specialized heavy installation teams.

International Compliance and Rigorous Quality

As equipment for global large-scale bulk markets, the ZOOMRY Bucket Wheel Stacker Reclaimer passes multiple international certifications and full-process quality control, ensuring compliant use across regions and long-term reliability under high loads.

International Certifications

CE certified (Machinery Directive 2006/42/EC, EMC 2014/30/EU), completing 15 specialized tests for heavy machinery safety, including structural strength (5x rated load simulation), emergency braking (≤0.6 s), electrical protection (IP65), EMC (resisting strong mining interference), direct EEA market entry; EAC certified for CIS countries’ “-30℃ low temperature, snowy mining” environments, Russian technical docs with low-temp bucket wheel lubrication and crawler anti-freeze maintenance; complies with ISO 9001 quality and ISO 14001 environmental management, fully traceable production from raw material inspection (bucket wheel manganese steel) to finished product, detailed records per process for batch consistency.

Full-Process Quality Control

ZOOMRY’s in-house quality center equips 60+ instruments like bucket wheel performance test benches, hydraulic high-pressure labs, structural mechanics testers for rigorous component testing:

• Bucket wheel system: blades pass “1000x 50 kg hard rock impact” and “1000-hour wear” tests, no significant wear/deformation;
• Crawler system: track shoes “500-hour soft ground travel,” wear ≤0.5 mm;
• Hydraulic system: 100-hour sealing (31.5 MPa), no leakage;
• Electrical system: 100-hour rain (IP65) and “200 m wireless anti-interference,” normal function.

Each unit undergoes 20 strict pre-delivery tests like “3000 m³/h full-load stacking/reclaiming,” “360° slewing precision,” “-30℃ cold start,” “crawler climbing (≤12° slope),” delivered only upon passing, ensuring reliable global mining/port large-scale operations.

Product Technical Parameters

Choosing ZOOMRY

Multi-Dimensional Efficiency and Cost Optimization

Selecting ZOOMRY Bucket Wheel Stacker Reclaimer delivers significant value to global mining and port customers in “processing efficiency, site adaptation, maintenance costs”:

• Efficiency Boost: 500-3000 m³/h wide range covers varied scales without separate equipment; PLC auto mode reduces manual intervention, 60% efficiency gain over traditional “loader+conveyor”; 360° slewing and crawler expand range, one unit replacing 2-3 fixed stacker reclaimers;
• Site Adaptation: 125-193 KPa low pressure suits soft ground, no leveling needed, cutting mining/port site prep costs; 15 m up/1 m down digging maximizes vertical stockpile capacity, enhancing utilization;
• Maintenance Optimization: High-wear components (Mn13 bucket wheel, nylon core belt) extend cycles, 50% less maintenance than ordinary; low failure (<0.6% annual) minimizes downtime, at 3000 m³/h saving ~1.8 million RMB/year; modular design allows partial replacement, 40% shorter maintenance time.

Service Support

ZOOMRY establishes “technical + spares + training” comprehensive system for global large-scale bulk projects:

• Technical Support: Multilingual docs (operation, maintenance, troubleshooting manuals) cover bucket wheel parameter optimization, crawler care, low-temp tips, with HD diagrams/videos; 24-hour online consultation, engineers respond ≤3 hours, all with 8+ years heavy bulk experience, familiar with mining high-load/port high-salt issues;
• Spares Assurance: Global supply chain pre-stocks bucket blades, track shoes, hydraulic filters, belts; DHL/FedEx shipping post-request, 5-10 days delivery by region; for key clients, “spares planning”—procurement/reserve plans based on intensity/cycles, bulk or phased replenishment preventing interruptions;
• Specialized Training: “Large-scale stacking/reclaiming training” (online live + on-site) includes path optimization, emergency handling (bucket jamming, derailment), daily maintenance, ensuring team mastery for mining/port high-load needs.