From 100 to 600+ t/h: Conversion engineering for cohesive limestone

How can an existing non-SCHADE bridge-type reclaimer designed for approximately 600 tonnes per hour achieve its intended capacity when challenging material behaviour limits actual performance to around 100 t/h? A new SCHADE Case Study shows how material investigation, DEM analysis and targeted conversion engineering were combined to develop a reclaiming concept around the actual behaviour of the cohesive limestone.

When the material defines the challenge

At a cement plant in the Far East, an existing non-SCHADE bridge-type reclaimer was generally in good condition and well maintained. Yet when handling the site’s cohesive limestone mixture, the machine was achieving only around 17% of its intended capacity.

Laboratory testing showed that the limestone became increasingly cohesive with rising moisture. Samples from the reclaiming pile, stacking pile and open quarry showed moisture contents of approximately 5.5–7.5%. The challenge was therefore not simply to modify the machine, but to understand the interaction between the bulk material, the existing equipment and its structural interfaces.

Engineered around the actual material behaviour

Before defining the conversion, SCHADE investigated the bulk-material behaviour and assessed the existing machine and its interfaces. Material testing, a 3D laser scan and DEM analysis provided the engineering basis for a new reclaiming concept designed to achieve at least 600 t/h across the investigated material conditions while integrating the new equipment into the existing reclaimer.

A new reclaiming concept for the existing machine

From material behaviour to machine design

The engineering behind the conversion

The new SCHADE Case Study provides further insight into the engineering behind the project – from bulk-material investigation and existing-machine assessment to 3D laser scanning, DEM analysis and the development and integration of the new reclaiming concept.

Discover how material-specific engineering transformed the requirements of cohesive limestone into the design basis for the new reclaiming system.

Download Case Study

Engineering solutions for demanding bulk-material handling applications

SCHADE develops customised solutions for the storage, stacking and reclaiming of bulk materials worldwide.

For further information or to discuss your project, please contact our SCHADE team:

sale@schade-lagertechnik.de