Reclaimer

RECLAIMER
A) Basic Principals and Concepts: -
In Sunflag Portal Bridge type Reclaimer installs by Space Age Engg Project Pvt.
Ltd. Pune. The Reclaimer is used to reclaims the material from stockpile and to
feed in process circuit through belt conveyor which is running along side.
Reclaimer reclaims material with the help of scraper chain, across the stockpile as
per requirement in process.
B) Sketch Diagram showing parts, identity :
RECLAIMER
C) Design features and specifications:
Description: - Reclaimer can be operated in two modes

a. Bridge mode
b. Portal mode
BRIDGE MODE: - In bridge mode scraper chain is exactly parallel to ground

level and harrow, which is attached on the structure, reciprocate continuously due
to which material slide down the stock pile. Scraper chain reclaims the same
material. In Bridge mode reclaimer travel on left side only i.e. stockpile on left
position of the reclaimer from cabin side. Travel speed in this mode is very slow
i.e. 0.5 to 5 mph. It regulates with the help of regulator.
PORTAL MODE: - In portal mode scraper chain is directly kept on stockpile i.e.
in inclined position and material reclaimed. This mode is generally used when
material pile has not sufficient height. In bridge mode total mixing of material
occur whereas in portal mode material came from top layer of the pile, so mixing
is not properly as harrow can not operated in portal mode. In portal mode speed of
the travel is 2 mph constant.
In bridge mode feeding can be increased with increasing in speed of travel and in
portal mode feeding increased when chain taken down on the material as per
requirement. There is one more speed i.e. traversing mode speed. It is generally
used to take reclaimer from one position to another position. Speed is 8 mph
maximum.
Main component: -
1. Boom with luffing mechanism
2. Scraper chain
3. Travelling mechanism/drives
4. Harrow
Specification: -
1. BOOM WITH LUFFING MECHANISM: -
Boom is the main part of the reclaimer. It is fabricated with structural steel and
section. Boom help to hold the total weight of scraper chain and travel over the
guide which are provided in boom structure. One end of boom is fixed and
attached with structure with the help of shaft which having support at both end
with the help of brg housing and can move like winch. Other end is free at up side
with steel rope through no of shieves (6 no.). Over these shives rope is transferred
to rope drum on which rope is wound or release. Drum gets rotation through
gearbox and motor. For safety thruster brake is provided in between motor and
gearbox. When rope wound on drum, boom go upward direction and when release
boom comes downward as per requirement. Luffing mechanism consist of
following parts:
* Gearbox: - Type- Helical Size- CKR 200

Ratio- 40:1 Make- Space Age
* Motor: - kW- 15 Rpm- 1500 Make- NGEF
* Input coupling- geared coupling 104
* Thruster brake- Drum Dia. 300 mm
2. Scraper chain: - It is another part of reclaimer. It consists of a links rotating on

toothed sprocket drive and driven sprocket, which are mounted on free end of
boom. Another end of drive sprocket is provided in between this two. One extra
idle wheel is given to take top side pressure to keep in position while travelling on
material called Idle Sprocket. On this chain pair bucket mounted at the position of
bucket either side of links (4 rollers at each bucket position called Track roller)
and one each alternately on both side from sideways called Guide roller are
provided. On track roller chain travel and reduce wear & tear of link part. Guide
rollers guide the chain to keep on sprocket. Chain of bucket are travel along the
length of boom top (away from cabin) and below cabin (towards cabin) i.e when
we saw from north end clockwise direction, from return side it take the material &
discharge on carrying belt (BC 4) through chute. For chain rotation drives are
provided with electric motor.
Main components: a. Bucket
b. Links/chain/sprocket
c. Track and Guide roller
d. Track
e. Gearbox/motor/coupling
a. BUCKET: - It is like sawel to take material from ground to belt by taking

support of hard ground. Total no of buckets are 118 made of magnise steel
material i.e. restrict the wear and tear.
b. CHAIN: - It is the roller bush chain. Pitch of chain is 250 mm on which
buckets are bolted. Chain having driven and driven sprocket on which it travels
and also buckets link tension can adjust manually as per requirement.
c. Track/guide roller: - Track roller is fixed either side of bucket at each pin of
chain. Numbers of track roller are 464. Guide rollers are kept in guide track on
which it travels. They are at about 2mt distance from each other. Number of roller
116.
d. TRACK: -Track is the portion welded to the boom from top & bottom side
through which chain roller travel. They are made from angle and internally liners
are provided which can be replacing it along the full of boom.
e. GEARBOX: - To drive chain through drive sprocket one gear unit is provided
with fluid coupling and motor. Chain speed is 24 mph.
Gearbox (1 no) Motor Fluid coupling
Type- Helical KW- 37 Type- SM6 12A
Size- DCR 360 Rpm- 1500
Ratio- 125:1 Make- NGEF
Make- Space Age
3) TRAVELLING MECHANISM: - Reclaimer is stand on four vertical wheels

fixed in four boogies. Two drive bogies, which are, placed diagonally and to non-
drive or idle bogie each having two guide roller. Vertical wheel of drive bogie gets
motion from gear unit through pinion and travel. Reverse and forward direction of
rail at both sides along yard. There is three speed in travel as stated. Travelling
length is 365-mt full length of yard.
* Gearbox: Type - helical Size- DKR 225
(2 no) Ratio- 63:1 Make- Space Age
* Gear Motor: 0.12 kW output rpm- 31
* Motor: 7.5 kW Make- NGEF
4) HARROW MECHANISM: -It is the mechanism of winch drive by rope

pulley; shieves rope and other end counter weight. These help for sliding the
material from stockpile with the help of spikes and trolley which travelling along
the boom structure in horizontal position. This mechanism used in bridge mode
only. Speed of harrow is 72 mph.
* Gearbox: Type- Helical Size- CKR 320
Ratio- 36:1 Make- Space Age
* Motor: KW-30 Rpm- 1000 Make- NGEF
* I/P coupling: Geared coupling 104
 Thruster brake: drum dia 400 mm
5) OTHER DETAILS: -
Reclaimer capacity- 114 Tph for coal
- 210 TPH for I/Ore
Weight of equipment- 110 MT (approx.)
Functions and applications:
It is used to reclaim the coal from the pile. When it runs in portal mode material
is reclaimed from the one side of the pile, when it runs in bridge mode material is
reclaimed through the cross section of the pile.
Handling and Maintenance practice :
Handling
1. Conveyor belt (BC 4)

2. Scraper chain
3. Harrow (for bridge mode only)
4. Travel drives
5. Boom luffing winch
Maintenance
1. Check gear box for oil level, temp., vibration or any other abnormality.
2. Check input and out put couplings and lubrication of bearings.
3. Check complete structure for welded joints and cracks.
4. Check fluid coupling for oil level and temperature.
5. Check functioning of thruster brake, adjust if required.
6. Check gear box internals and bearings by opening top cover and replace all
defective parts.
7. Check wear of traveling wheels.
8. Lubricate slewing bearing.
9. Check discharge chute of boom belt.
10.Check track and side rollers for jamming.
11.Check track liner plate for wear.
12.Check bucket bolts for tightness.
Problems and Solution
Problem Solution
Brake is not working  Check the gap of thruster and adjust
Scrapper chain is not  Check thruster bearing and adjust the gap.
lifting
Reclaimer is not traveling  Check whether limit switch is free or
material is obstructing it, if so clean the
material.
Track liner plate is worn  Replace the liner plate.
out
Track rollers are missing  Replace track rollers
Emergency Handling
1. If reclaimer discharge chute is gets jam, stop reclaimer and clean chute.
2. If harrow rope is found broken, stop reclaimer and replace the rope shift the
trolley towards the drive end of chain and run the reclaimer in portal mode.
3. Slow drive is not running , stop it and check magnetic coupling gap.
Safety and House-Keeping
1. Use all safety appliances while working.

2. Before starting the equipment hooter should blow.
3. While cleaning, cotton waste and used grease should be kept in dust bin.
4. There should be no leakage of oil on floor.
5. Extra material (nut, bolts, spares, scrap etc.) lying on floor should be removed
immediately after completing the job.
Reaction Plan
1. If guide rollers are found jammed, repair / replace them.

2. If bucket bolts are loose ,tight the bucket bolts.
3. If few consecutive track rollers are missing fix new track rollers.
4. If buckets are bend ,replace with new one.
Proactive Plan
1. Check input and output couplings for any abnormal sound.

2. Check gear box for any vibration, temp. and abnormal sound.
3. Check bearings for any abnormal sound and temp.
4. Check reclaimer travelling gear box motor, scraper chain motor, harrow motor
and scraper chain lifting motor for their normal current.
5. Clean area both side of the rails.
6. Change skirt rubber of scraper chain discharge chute.
Waste Control Measures
Good and Bad Practices
1. Do not stand on the rails while it is traveling.

2. Hooter should blow before starting.
3. While running the reclaimer stacker boom should not be near the reclaimer.
Frequently Ask Questions
Q.1 What is the type of Reclaimer.

Ans. It is bridge and portal type .
Q.2 What is bridge mode?
Ans. Harrow runs across the cross section of the pile & agitate the material, the
fallen material on the ground is carried by scraper chain. Reclaimer travels
on rails along the pile on slow drives.
Q.3 What is portal mode?
Ans. Reclaimer runs on rails along the pile with lifted scraper chain boom
touching over a face of pile .
Q.4 Which type of coupling is used in slow drive?
Ans. Magnetic coupling.
Q.5 What is the advantage of magnetic coupling?
Ans. Whenever we switch over from D.C. drive to A.C. drive it decouples
automatically or vice versa.
Q.6 What is the normal current of slow drive?
Ans. 0.3 Amps. (approx.)
Q.7 By what method motion is provided to Harrow, Scraper chain boom?
Ans. Winching action.
Q.8 What is the capacity of Reclaimer?
Ans. For iron ore -250 tph
Coal -114 tph
Q.9 What is the function of scraper chain?
Ans. It carries the material from the pile and discharges it over B. C.- 3.
Q.10 Why scraper chain is kept in horizontal position in Bridge mode?
Ans. If scraper chain is not horizontal drive of harrow will take more load while
trolley is moving towards high end of scraper chain.

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What are the two modes of operation of a reclaimer?

What are the two modes of operation of a reclaimer?

What is the difference between bridge mode and portal mode?

What is the difference between bridge mode and portal mode?

RECLAIMER

A) Basic Principals and Concepts: -

B) Sketch Diagram showing parts, identity :

Description: - Reclaimer can be operated in two modes

BRIDGE MODE: - In bridge mode scraper chain is exactly parallel to ground

* Gearbox: - Type- Helical Size- CKR 200

2. Scraper chain: - It is another part of reclaimer. It consists of a links rotating on

a. BUCKET: - It is like sawel to take material from ground to belt by taking

3) TRAVELLING MECHANISM: - Reclaimer is stand on four vertical wheels

4) HARROW MECHANISM: -It is the mechanism of winch drive by rope

Handling and Maintenance practice :

1. Conveyor belt (BC 4)

Problems and Solution

Safety and House-Keeping

1. Use all safety appliances while working.

1. If guide rollers are found jammed, repair / replace them.

1. Check input and output couplings for any abnormal sound.

Good and Bad Practices

1. Do not stand on the rails while it is traveling.

Frequently Ask Questions

Q.1 What is the type of Reclaimer.

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