Drawdown Hoppers & Flow Control

Stockpile
Reclaim Systems

A DIVISION OF HALLEY & MELLOWES GROUP OF COMPANIES

 Drawdown Hoppers
Material Handling Solutions

Drawdown Hopper

The Carman Drawdown Hopper is designed for all types of outdoor storage piles. The discharger’s Projection
Ring transmits vibrations throughout the pile, encouraging “slough-in”. Wet and frozen materials such as coal,
potash, salt and aggregate come to life and flow from outside storage reclaim piles.

Greater Efficiency from Vibration

Estimated Reclaim = 640 Tons with Drawdown The Vibratory Drawdown Hopper is
= 150 Tons without Drawdown
located at ground level below the
stockpile, and its function is to provide
the initial flow stimulation. Once product
Static movement is established the flow rate
Reclaim Angle
is regulated by the Flow Control Gate.
Overall control is achieved by linking a
38Ft.

downstream belt weigher to the Flow

Dynamic 85° 37° Control Gate operation.
Reclaim
Angle

45° This system can provide 80% more

8Ft. Diameter
live reclaim compared to a static hole,
and is a very effective and cost efficient
method of stockpile reclaim.
 Stockpile Discharge Problems
Minimal Active Reclaim
By utilising a static hopper and
feeder, active reclaim is limited
to within approximately 40° of
the stored material’s natural
angle of repose.
How the Drawdown Hopper eliminates these problems
Maximise Active Reclaim
Carman Drawdown Hoppers
consistently increase active
reclaim to within 5 to 10 degrees
of a material’s natural angle of
repose. A Carman Drawdown
Hopper can provide 4 to 5 times
the reclaim of an equally sized
static hopper with a feeder.
Bridging
Bridging is the archlike formation
of material over either the static
hopper inlet or outlet. It results
from improperly designed hoppers
or when the outlet is too small.
Bridging Solution
Carman Drawdown Hoppers have
command of the material equal
to the Drawdown diameter. This
results in an initial flow column equal
in diameter to the overall diameter
of the Drawdown Hopper. A highly
visible flow steam also improves
on-pile equipment operator safety.
Coring
Coring occurs when the material
in the core of the pile discharges,
while material on the periphery
resists movement.
Coring Solution
The projection ring of the
Carman Drawdown Hopper,
which is always exposed to the
pile, transmits vibration and
energy directly into the pile. This
eliminates coring and maximises
active reclaim.
 Drawdown Hoppers
Material Handling Solutions
Flow Control Methods
Vibrating feeder
The Drawdown Hopper and
vibrating feeder has been used
for many years and has proven a
reliable method to reclaim material
from a stockpile. The vibrating
feeder is well suited to handle
small to moderate flow rates.
“Swing hopper”
Flow Control Gate
With the requirement for larger
reclaim rates other systems were
developed. The Halley & Mellowes
“Swing Hopper” Flow Control
Gate was designed to enable large
flow rates up to 6,000 tonnes per
hour (coal) to be controlled. With
only one moving component, this
system will allow variable discharge
rates by position adjustment of
a pivoted swing hopper against
a stationary curved floor. When
adjusting the swing hopper away
from curved floor, an open area
is created to allow material flow.
The volume of material discharged
varies depending on gate position.
This system has been installed
in a large number of locations in
Australia and overseas, and has
been operating reliably for more
than 20 years.
Low Headroom NEW
Flow Control Gate
The latest development to regulate
material flow is the Low Headroom
Flow Control Gate. This gate is a
heavy-duty bi-parting slide gate
designed by Picor (US), and it
incorporates a range of unique
design features. It was introduced in
Australia a few years ago by Halley
& Mellowes in response to a call for
lower headroom in reclaim tunnels.
This new Low Headroom Flow
Control Gate has been installed in a
number of recent Australian projects
and is performing reliably as it has
done overseas for many years.
The benefits of this gate:
- Reduced reclaim chamber head
height (by over 2 metres). This
reduces excavation and concrete
structure costs.
- Reduced capital cost by 50%
- Non-stop infinite modulating
control. Hydraulic power source
allows instant flow rate change in
response to weigh scale signals.
- Easy low maintenance (no rollers).
This gate uses low friction HD
polymer blocks with long lifespan.
- Fail-safe close. Hydraulic
accumulator immediately closes the
Flow Control Gate in the event of
power failure, ready for restart.
Projection Ring:
Carman’s unique Projection Ring is
always in contact with the storage
pile. Better flow stimulation and high
reclaim percentages result from the
controlled transmission of vibratory
energy.
Patented Rubber Isolators:
Carman’s patented isolators system
was developed to support the
enormous loads encountered under
a storage pile. Specifically designed
for use with Drawdown Hoppers,
molded rubber isolators are totally
non-restraining to allow more motion
more flow stimulation, less power
consumption and maximum reclaim.
The chamfered top of each isolator
allows improved isolation under all
conditions from full to no-load.
Complete Range of Construction
Materials and Liners:
Carman provides a complete range
of construction materials and liner
choices, including various grades
of stainless steel, abrasion resistant
steel, epoxy and urethane. Whether
your application is coal, wood,
fertiliser, salt, iron ore, tailings or
something else Carman can supply
the proper construction materials.
Drive Motor:
Carman’s Drawdowm Hopper has
separate electrical and mechanical
drive components for reliability and
ease of maintenance. A standard
1800 rpm, TEFC foot-mounted motor
transmits power though a belt drive
to the centrifugal force exciter.
Centifugal Force Exciter:
The low frequency, long stroke
action of the force exciter generates
the high energy required for
maximum reclaim. Carman’s
centrifugal force exciter consists
of adjustable eccentric weight
mounted on a single shaft and
supported by bearings. Grease
lubricated double roll spherical
bearings assure long life. The
exciter is easily accessible for
maintenance and serviceability.
 Drawdown Hoppers
Material Handling Solutions

Applications

Problem:
An ore mine was experiencing periodic shutdowns due to
an inadequate method of handling mine tailings. Constant
attention and excessive manpower was required to
permanently dispose of refuse.

The Solution:
A waste system was installed which included 10 Carman
Drawdown Hoppers with reclaim capability of 14,500 tons.
The Drawdown Hoppers feed a conveyor system leading to
a permanent refuse facility. Shutdowns have been replaced
by immediate, uninterrupted flow of refuse material.

Problem:
An lowa power company required a reliable active reclaim
system which would insure positive flow to fuel preparation
equipment.

The Solution:
Application data was analysed and four Drawdown Hoppers,
symmetrically placed around the stacking tower provide a
positive and continuous material source for feeders located
in the tunnel. The concrete pads provide a flush, bulldozer-
proof installation.

Problem:
A cogeneration facility in North Carolina required maximum
reclaim and equipment reliability in the reclamation of
coal for boilers.

The Solution:
Carman recommended two Drawdown Hoppers located
in each side of two stacking tubes. Field tests conducted
by the customer report the reclaim achieved is nearly
identical to that predicted.
60 Degree Cone Design:
After testing many cone
configurations, our 60 degree
design has proven to be the
most effective for Drawdown
Hopper performance. Its
60 degree cone promotes
steady flow eliminates
dormant area associated
with other configurations.
Installation Ease:
No other reclaim device
installs as easily as a Carman
Drawdown Hopper – we
guarantee it. Our units come
absolutely complete, ready
to install. All you supply is the
crane. Premounted isolators
and installation hardware
are provided.
Cycled Operation:
Carman’s unique design
permits cycling of the
unit to achieve maximum
reclaim. Cycling produces
uniform flow, longer exciter
life and reduced power
consumption.
 VIC
Melbourne
11/97 Bayfield Road East, Bayswater VIC 3153
Tel: +61 (0)3 8720 6700
Fax: +61 (0)3 8720 6799
NSW Email: melbourne@hmagroup.com.au
Wyong - HMA Group Head Office Morwell
10 Hereford Street, Berkeley Vale NSW 2261 8 Jones Road, Morwell VIC 3840
PO Box 5010 Chittaway NSW 2261 Tel: + 61 (0)3 5136 8400
Tel: +61 (0)2 4389 6191 Fax: +61 (0)3 5136 8499
Fax:+ 61 (0)2 4389 6199 Email: morwell@hmagroup.com.au
Email: info@hmagroup.com.au

Sydney NT
13 Sirius Road, Lane Cove NSW 2066 Darwin
Tel: +61 (0)2 9428 7300 4/69 Aralia St, Nightcliff, NT 0810.
Fax: +61 (0)2 9428 7399 Tel: +61 (0)8 8948 5122
Email: sydney@hmagroup.com.au Mobile: +61 (0) 437 460 052
Fax: +61 (0)8 6254 9599
Singleton
Email: darwin@hmagroup.com.au
21 Magpie St, McDougall’s Hill, NSW 2330
Tel: +61 (0)2 6571 8200
Fax: +61 (0)2 6571 8299
NEW ZEALAND
Email: singleton@hmagroup.com.au Hamilton
Unit 9, 9 Karewa Place, Pukete, Hamilton NZ 3200
QLD PO Box 10102, Te Rapa Hamilton NZ 3241
Tel: +64 (0)7 850 2610
Brisbane
Fax: +64 (0)7 847 1883
Building 107, unit 3B, 2-6 Leonardo Drive,
Email: hamilton@hmagroup.co.nz
Hamilton Central, QLD 4007
PO Box 999, Hamilton Central, QLD 4007 Dunedin
Tel: +61 (0)7 3859 6800 Mobile: +64 (0) 275 116 694
Fax: +61 (0)7 3859 6869 Email: dunedin@hmagroup.co.nz
Email: brisbane@hmagroup.com.au

Mackay
INDONESIA
22-30 Southgate Drive, Jakarta
Southgate Industrial Park, Paget QLD 4740 Jl. Adhyaksa Raya Blok W No.11
PO Box 6221, Mackay Mail Centre QLD 4741 Kel. Lebak Bulus Kec. Cilandak
Tel: +61 (0)7 4998 6900 Jakarta Selatan 12440
Fax:+61 (0)7 4998 6999 Indonesia
Email: mackay@hmagroup.com.au Phone number: +62 21 29124898
Fax: +62 21 7512211
Gladstone Email: jakarta@hmagrp.com
9 Neil St, Gladstone QLD 4680
PO Box 1731, Gladstone QLD 4680 SOUTH AFRICA
Tel: +61 (0)7 4973 5500
Johannesburg
Fax: +61 (0)7 4973 5599
Quadrum Office Park Building 4
Email: gladstone@hmagroup.com.au
50 Constantia Boulevard, Constantia Kloof
Johannesburg 1709, South Africa
WA
Tel:+27 115 348 523
Perth Fax:+27 115 348 401
119 Dowd Street, Welshpool WA 6106 Email: johannesburg@hmagrp.com
Tel: +61 (0)8 6254 9500
Fax:+61 (0)8 6254 9599
Email: perth@hmagroup.com.au

Halley & Mellowes Australasia Group of Companies

Geotechnical
Systems Australia

08/14