Stockpile Coal Handling

EPHB-Sec23-11:EPHB-Sec23-11
10/26/10
1:06 PM
Page 1
STOCKPILE COAL HANDLING

CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . .23-1
Machine Selection . . . . . . . . . . . . . . . . . . . . . . .23-1
How to Equip . . . . . . . . . . . . . . . . . . . . . . . . . .23-2
Production Factors . . . . . . . . . . . . . . . . . . . . . .23-2
Estimating Hourly Production . . . . . . . . . . . . .23-3
Track-Type Tractors . . . . . . . . . . . . . . . . . . .23-4
Wheel Dozers . . . . . . . . . . . . . . . . . . . . . . . . .23-5
Wheel Loaders . . . . . . . . . . . . . . . . . . . . . . . .23-7
Wheel Tractor-Scrapers . . . . . . . . . . . . . . . .23-8
Example Problem . . . . . . . . . . . . . . . . . . . . . . .23-9
INTRODUCTION
Efficient methods have been developed for handling
and storing coal with mobile equipment. Generally, a
power plant or other industrial facility which uses
coal, meets its daily requirements with incoming coal
shipments and will maintain an emergency stockpile
or deadpile. The deadpile is designed to meet the
burn requirements during any interruption of coal
shipments. Interruptions may include inclement
weather, carrier strikes, scheduling problems, etc.
The deadpile will contain approximately a 90 day
supply of coal and is constructed by thoroughly compacting lifts, or layers, of coal approximately 15 cm
(6 in) thick. Thorough compaction of the entire stockpile, including the sides, eliminates air spaces, reducing the possibility of spontaneous combustion.
Reclaiming the deadpiled coal is critical when
incoming shipments are not able to satisfy the burn
requirements. Four basic types of mobile equipment
are available for stockpiling and reclaiming coal
track-type tractors, wheel dozers, wheel loaders,
and wheel tractor-scrapers. Each type has its own
specific advantages. The equipment selected must
be able to meet the maximum hourly burn rate.
MACHINE SELECTION
Track-Type Tractors
Track-type tractors continue to be the most widely
used machines for coal handling operations.
Equipped with a U-shaped coal dozer, they are suitable for meeting high production requirements over
dozing distances of less than 152 m (500 ft). Their
tractive capabilities and gradeability permit them to
operate on the sides of the stockpile and surge pile

which often prove inaccessible to other types of
equipment. They can also remove snow and frost
penetrated coal from the stockpile surface so that
rubber-tired equipment can work efficiently.
Wheel Dozers
These machines, with their long wheel base, low
center of gravity, and articulated design, offer good
stability and maneuverability. They have the ability to travel at a higher speed than the track-type
tractor, moving easily from one area of operation to
another, and provide greater compactive effort with
fewer passes. They are capable of performing some
utility functions. However, their coefficient of traction is less than that of track-type tractors. The most
efficient dozing distance for the wheel dozers is usually less than 152 m (500 ft).
Coal scoops are also available for wheel dozers
and may improve production under certain operating conditions.
Wheel Loaders
As dozing and hauling distances increase, wheel
loaders are able to effectively move coal in load-andcarry operations. Since coal is a relatively light
material, the loaders should be equipped with larger
buckets sized for coal density. Versatility and mobility allow them to perform a variety of tasks, both
on and off the stockpile. They can load trucks or railcars, dig out bottom ash and boiler slag from the
ash storage areas, and move railcars within the vicinity of the power plant. Generally wheel loaders are
more efficient than track or wheel dozers at distances of 122 m (400 ft) or more.
Coal Bowl Wheel Tractor-Scrapers
Coal Bowl Wheel Tractor-Scrapers are typically
used for building and maintaining coal stockpiles
and hauling coal to the supply system at coal power
plants. The self-loading capability, large capacity,
coal pile compaction, and high speed of Coal Bowl
Wheel Tractor-Scrapers make them the tool of choice
for moving coal both short and long distances. Coal
Bowl Wheel Tractor-Scrapers are available in the
637G and 657G tandem engine models. Please reference section 8 of this handbook for more information on Coal Bowl Wheel Tractor-Scrapers.
Edition 41
23-1
23
10/26/10
Stockpile Coal Handling
1:06 PM
Page 2
How to Equip
Production Factors
HOW TO EQUIP
Counterweighting
While larger blades or buckets allow for greater
production, counterweighting is often necessary to
improve the machines balance and handling capability. For track-type tractors, a rear counterweight
is recommended. Wheel machines use various methods to add weight. For example, scoop dozers use
front counterweights, and wheel machines often use
tire ballast. Below is a weight comparison of the Cat
standard U-blade to the Coal Dozer, along with the
recommended counterweight for D11T, D10T, D9T,
D8T, and 834H.
COAL STOCKPILE BLADE WEIGHT COMPARISON/
COUNTERWEIGHTING
Model
D11T
D10T
D9T
D8T
834H
U-Blade
kg
lb
11 608
6188
4179
2825
2994
25,590
13,643
,9214
,6228
,6600
*834H with Scoop
Coal Dozer/
Scoop
kg
lb
11 340
6440
4490
3200
3630
25,000
14,200
,9900
,7050
,8000
8700
19,180
Counterweight
kg
lb
4989
11,000
2928
,6456
3142
,6926
2749
,6060
75% CaCI2 in all
tires
5360
11,816
Weights include blade or scoop only. The change in machine weight is determined
by adding or subtracting the difference between the two blades. Counterweight
or ballast may also need to be considered.
Other
The 834Hs performance may be improved in the
varying underfoot conditions of a coal stockpile with
the use of a Detroit NoSPIN differential. This differential provides added tractive capability on all
coal piles, particularly loose coal.
PRODUCTION FACTORS
1. The effect of grade dozer production will
increase 3% for each 1% of favorable grade and
decrease 2% for each 1% of adverse grade up to
grades of 10%. The graph below exemplifies this
point.
Effect of Grade on Production
% Grade
Favorable
Unfavorable
Production Correction Factors
Track Shoe Width

Track shoes are an important consideration since
shoe width determines tractive capability and compaction. Depending on the coal being stockpiled, the
utility company will often have a strong preference
concerning track shoe width. Basically, utilities
stockpiling low rank or sub-bituminous rank lignite
coal usually prefer the standard shoe width for maximum compactive effort to reduce the possibility of
spontaneous combustion.
Utilities burning medium or high rank bituminous
coals are not as concerned with spontaneous combustion and sometimes prefer a wider shoe that allows
increased tractive capability on loose or less densely
compacted coal stockpiles.
Tires
Many utility companies have established a tire
preference for wheel machines. Normally a radial
tire allows for the maximum tire print in the stockpile surface providing the best traction.
Tire pressure may be of equal importance to tire
selection. Tests with hydro-inflated (liquid ballasting)
tires indicate that inflation pressure of approximately 275 kPa (40 psi) improves machine performance over higher inflation pressure. Lower than
275 kPa (40 psi) is not recommended for hydroinflated tires. (For more hydro-inflation information see the Tire section.)
As a rule of thumb, track-type tractors can negotiate grades of about 60% in loose
coal. Wheel dozers can negotiate grades up to 25% on fairly well compacted coal.
23-2
Edition 41
10/26/10
1:06 PM
Page 3
Production Factors
Estimating Hourly Production
2. Slot dozing, which consists of dozing repeatedly

in the same tracks, will increase production. The
deeper the slot, the greater the increase in production. Obviously this will disrupt the surface of the
pile; however it does provide maximum production.
Slot
Condition
Slot
Depth
Increase
in Production
Slight
Consistent
Very Consistent
60 cm 2 ft
60 cm-1.5 m 2-5 ft
Over 1.5 m Over 5 ft
10%
25%
30% +
5. The degree of compaction required for medium

and high rank bituminous coal, track-type tractors
will normally provide ample compaction to prevent
fires. For low rank coals, such as sub-bituminous
and lignite, rubber tired machines, pneumatic compactors or sealing may be required to prevent fires.
The following table illustrates the compaction that
is possible if the coal is spread in thin lifts and the
machine makes a sufficient number of passes over
the entire lift surface.
Machine
3. Relative traction machines will provide greater

tractive effort as the compaction beneath them
increases.
Condition
Well Compacted Coal
Loose Coal
Machine
Coefficient
of Traction
Track-type
Wheel
Track-type
Wheel
*0.75-0.80
*0.40-0.50
*0.60-0.00
*0.30-0.40
*D11T, D10T, D9T and D8T will often achieve a higher coefficient of traction due
to their suspended undercarriage.
4. Rolling Resistance of rubber tired equipment will

decrease as the compaction of the coal beneath the
machines increases. Here are total rolling resistances on various surfaces.
Main travel area from

loading area to stockpile
traveled and maintained.
Travel over the compacted
deadpile.
Travel over thin lifts of
uncompacted coal on the
deadpile.
Travel on loose piles under
stacking conveyor or
on a windrow.
kg/Metric lb/U.S.
Ton
Ton
29
65
36
80
54
120
90136
200300
Track-Type Tractors
Wheel Dozers
Wheel Loaders
Wheel TractorScrapers
kg/m3
lb/ft3
lb/yd3
960-1160
1040-1200
1040-1250
60-72
65-75
65-78
1620-1950
1750-2030
1750-2110
1100-1280
68-80
1840-2160
ESTIMATING HOURLY PRODUCTION

The following graphs may be used for estimating
the hourly production of machines handling mixed
bituminous coal. The graphs are based on 100%
machine efficiency under normal job conditions and
average operator; they do not take into account
adverse grades, downtime, wait time, poor traction,
etc. These production estimates should be evaluated
in light of individual job conditions and efficiency.
Moreover, a job efficiency correction factor should
be applied to the production estimate shown when
using these graphs.
To estimate travel times for a specific machine
refer to the performance graphs or charts in the
appropriate model section of this book.
NOTE: Capacities and production curves on the next
pages are based on bituminous coal with a
density of 890 kg/m3 or 1500 lb/yd3 or 55 lb/ft3.
For sub-bituminous coal with a density of
800 kg/m3 or 1350 lb/yd3 or 50 lb/ft3 multiply
tonnage figure by 0.90. For lignite with an
average density of 710 kg/m3 or 1200 lb/yd3
or 45 lb/ft3 multiply tonnage figure by 0.80.
Edition 41
23-3
23
10/26/10
1:06 PM
Page 4
Estimated Hourly Production

Track-Type Tractors
Track-Type Tractors Estimated Production

with U-Blade (Coal Dozer)
Factors:
Mixed Bituminous Coal
Storage and Reclamation
0% Grade
0.80 Coefficient of Traction
(Tons per 60-Minute Hour)
English
Short Tons
PRODUCTION IN TONS/HR
Metric
Tons
NOTE: This chart is based on numerous field studies made under

varying job conditions. Refer
to correction factors following
these charts.
Feet
Meters
DOZING DISTANCE (ONE WAY)
U-Blade
Tractor
D11T
D10T
D9T
D8T
D7R2
D6R
Blade Capacities
Model
ft
Metric tons
U.S. tons
m3
yd3
BD11U-24
BD10U-20
BD9U-19
BD8U-18
BD7U-16
BD6U
7.32
6.10
5.79
5.49
4.88
4.27
24'
20'
19'
18'
16'
14'
66.70
40.85
32.60
19.00
14.28
08.84
73.50
45.00
35.90
21.00
15.75
09.75
74.90
45.90
37.00
21.40
16.05
09.90
98.0
60.0
48.0
28.0
21.0
13.0
Refer to Track-Type Tractor/Bulldozer section for additional special attachment specifications.
23-4
Edition 41
10/26/10
1:06 PM
Page 5

Wheel Dozers
Wheel Dozers Estimated Production

with U-Blade (Coal Dozer)
NOTE: This chart is based on numerous field studies made under

varying job conditions. Refer
to correction factors following
these charts.
Factors:
0% Grade
23
Metric
Tons
English
Short Tons
4000
854K
3600
3500
3200
2800
2400
844H
3000
2500
834H
2000
1600
2000
824H
1500
814F II
1200
1000
800
400
0
500
0
0
200
50
400
100
600
150
800
200
1000
250
300
1200
350
Feet
Meters

U-Blade
Blade Capacities
Tractor
Model
ft
Metric tons
U.S. tons
m3
yd3
854K
844H
834H
824H
814F II
153-2113
153-2111
BD834U-20
BD824U-15
BD814U-14
7.20
5.84
6.17
4.79
4.32
23'8"
19'2"
20'3"
15'9"
14'2"
38.19
26.23
18.80
14.20
09.40
42.26
29.02
20.80
15.70
10.30
44.7
30.7
22.0
16.1
11.0
58.2
40.2
29.0
21.0
14.0
NOTE: Blade capacities in tons figured using weight of coal at 890 kg/m3 (1500 lb/yd3).
Edition 41
23-5
10/26/10
1:06 PM
Page 6

Wheel Dozers
Wheel Dozers Estimated Production

with Coal Scoop
Factors:
0% Grade
English
Short Tons
Metric
Tons
Feet
Meters
Scoop Capacities
(Lift and Carry)
Coal Scoop
Doze
Capacities
Tractor
Model
ft
Metric tons
U.S. tons
m3
yd3
Metric tons
U.S. tons
m3
yd3
834H
814F II
B34-26
B14-15
5.3
3.7
17'4"
12'3"
18.3
08.2
20.2
09.0
19.9
11.5
26
15
37.5
16.3
41.25
18.00
37.5
19.1
49
25
23-6
Edition 41
10/26/10
1:06 PM
Page 7

Wheel Loaders
Wheel Loaders Estimated Production

with Coal Bucket
Factors:
0% Grade
23
English
Short Tons
Metric
Tons
Feet
Meters
HAUL DISTANCE (ONE WAY)

Coal Bucket
Bucket Capacities
Loader
Model
Metric tons
U.S. tons
m3
yd3
992K
294-9020
275-9590
253-4080
B80-11
B66-7
16.83
20.19
11.44
7.30
4.80
18.61
22.33
12.65
8.10
5.30
19.11
22.93
12.99
8.20
5.50
25.00
30.00
17.00
10.75
07.25
988H
980G
966G
*Information unavailable at time of printing.

NOTE: Bucket capacities include bottom cutting edge in tons figured using weight of coal at 890 kg/m3
(1500 lb/yd3).
Edition 41
23-7
10/26/10
1:06 PM
Page 8

Wheel Tractor-Scrapers
Wheel Tractor-Scrapers Estimated Production

Factors:
0% Grade
Metric English
Tons Short Tons
657G
637G
Feet
Meters
HAUL DISTANCE (ONE WAY)
Bowl Capacities
Coal
Scraper
Metric
tons
U.S.
tons
m3
Struck
yd3
m3
Heaped
yd3
657G
637G
49.9
34.5
55
38
45
31
59
41
56
38
73
50
Average fixed time to load, maneuver and dump:

657G 1.12 min.
637G 1.10 min.
NOTE:
The 657G Coal Scraper is 1072 mm (42.2") longer,
the bowl sides are 1010 mm (39.8") taller, the apron
is 677 mm (26.7") taller, and the ejector is 944 mm
(37.2") taller than its earthmoving counterpart.
The 637G Coal Scraper is 736 mm (29.0") longer,
the bowl sides are 476 mm (18.7") taller, and the
apron is 499 mm (19.6") taller than its earthmoving counterpart.
23-8
Edition 41
The rimpull, travel times, and retarder performance

for the coal scrapers are the same as for the standard machines. See Wheel Tractor-Scrapers section for charts and graphs.
10/26/10
1:06 PM
Page 9
Example Problem
Example Problem
A coal-fired utility company has a coal requirement of approximately 315 metric tons (350 tons) per
hour. Specify the coal handling machine that will
satisfy this demand.
Conditions:
Lignite Coal 710 kg/m3 (1200 lb/yd3)
90 m (300 ft) push distance
5% adverse grade
50 minute hour operation efficiency
Solution:
Calculate the D9Ts production equipped with the
BD9U-19 Coal U-Blade by using the D9T production curve. Start at 90 m (300 ft) and read up to the
D9T production line, then over to the left to determine its maximum hourly production of 612 metric
tons (675 tons).
Since the graphs are based on a 890 kg/m 3
(1500 lb/yd3) coal density, this production figure has
to be adjusted to reflect lignite coal:
Coal density correction factor = 710/890 (1200/
1500) = 0.8.
Obtain the production correction factor for the 5%
adverse grade from the chart: 0.9.
The correction factor for the 50 minute hour is

50/60 = 0.83.
Now calculate the adjusted D9T hourly production using the correction factors:
Metric 612 .8 .9 .83 = 366 tons/hour
English 675 .8 .9 .83 = 403 tons/hour
The D9T falls in the required production range.
For short periods of peak power capacity, production could be increased by slot dozing.
Production for the D10T, 824H and 834H can be
calculated using the same method.
D10T
Metric 850 .8 .9 .83 = 508 tons/hour
824H
Metric 400 .8 .9 .83 = 239 tons/hour
834H
Metric 689 .8 .9 .83 = 412 tons/hour
Therefore, the D9T or 834H could most economically satisfy the production requirements.
Edition 41
23-9
23
Notes
23-10
Edition 41
10/26/10
1:06 PM
Page 10

Stockpile Coal Handling - Sec 23

Uploaded by

Copyright:

Available Formats

Stockpile Coal Handling - Sec 23

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Stockpile Coal Handling - Sec 23

Uploaded by

Copyright:

Available Formats

What are the four main types of mobile equipment used for stockpiling and reclaiming coal?

What are the four main types of mobile equipment used for stockpiling and reclaiming coal?

What are some advantages of wheel dozers compared to track-type tractors?

What are some advantages of wheel dozers compared to track-type tractors?

EPHB-Sec23-11:EPHB-Sec23-11

operate on the sides of the stockpile and surge pile