A stationary stacker is a fixed conveyor system designed for stockpiling bulk materials in permanent processing plants.

Unlike portable stackers that can be moved between sites, stationary stackers are permanently installed and form the long-term material handling infrastructure of mining, quarrying, and industrial operations. They are available in two main configurations: fixed stackers, which discharge at a stationary point, and radial stackers, which rotate around a pivot to create larger stockpiles.

Stationary stackers serve multiple applications across various industries. Key applications include:

Aggregate quarries: Stockpiling crushed stone, sand, and gravel for construction markets.

Mining operations: Stacking ore, overburden, and processed minerals in permanent stockyards.

Cement plants: Stockpiling limestone, clay, and other raw materials for continuous feed to kilns.

Power plants: Stacking coal for fuel storage and blending.

Port and terminal facilities: Building large stockpiles for ship loading and unloading operations.

Industrial minerals: Handling materials like salt, potash, and fertilizers in permanent facilities.

The fundamental difference lies in their ability to move during operation:

A fixed stacker discharges material at a stationary point. Once installed, its discharge position remains unchanged unless structural modifications are made. It features a simple, cantilevered design that extends over the stockpile without supports that would be buried in the material.

A radial stacker rotates around a central pivot point near the tail end, allowing material to be distributed in a circular or arc-shaped pattern. The entire frame is mounted on wheels and can move in an arc around the pivot, creating large, kidney-shaped stockpiles that maximize capacity on the same footprint.

A fixed stacker operates through a straightforward process:

Material feed: Material is fed onto the conveyor at the tail end from upstream processing equipment.

Inclined transport: The belt carries material up the inclined truss to the discharge point.

Stockpile formation: Material discharges from the cantilevered head end, falling onto the stockpile below.

Pile growth: As the pile grows, material falls from increasing height, which can create dust and segregation issues.

Reclaiming: Material is typically reclaimed from the stockpile via tunnel conveyors underneath or by mobile equipment.

A radial stacker operates through a continuous, automated process:

Material feed: Material enters the feed boot at the tail end, typically from upstream processing equipment.

Inclined transport: The belt carries material up the truss to the discharge point.

Radial movement: The entire stacker rotates around its pivot point, distributing material in an arc.

Height adjustment (variable models): The boom raises gradually as the stockpile grows, maintaining optimal drop height to minimize dust and segregation.

Stockpile formation: The combination of radial movement and height adjustment creates large, kidney-shaped stockpiles with maximum capacity.

Automated operation: Many modern radial stackers feature ultrasonic sensors that automatically control slewing and luffing for hands-free stockpiling.

The choice depends on your operational priorities and application:

Choose a Fixed Stacker when:

Your process is stable and continuous with a single material type.

Initial capital cost is the primary concern.

The installation is permanent with no planned changes.

You have ample land for stockpiling and don't need to maximize capacity.

Your operation can accommodate loader rehandling of material.

You're in industries like cement plants, power plants, or fertilizer facilities with consistent throughput.

Choose a Radial Stacker when:

You need maximum stockpile capacity on limited land.

Operational flexibility is critical for your operation.

You want to reduce loader dependency and lower operating costs.

Your application involves multiple materials or changing specifications.

Dust control and environmental compliance are priorities.

You're in aggregate quarries, mining operations, or bulk port terminals.