Manufacturing Ingenuity, Product Advancements Create New Possibilities for Aggregates Producers.
By Mark S. Kuhar
Aggregates production is a bit like baseball. You could argue that blasting, loading and crushing are the starting pitchers doing the grunt work, while screening, sizing and washing are the specialty relievers that come out of the bullpen to finish the job. That is indeed a combination that leads to a winning team.
Screening manufacturers are always finding new ways to improve products and process. Here are some of the latest innovations designed to keep you in the game.
Buffalo Wire Works
Buffalo Wire Works offers a premium, mill-rolled perforated plate that provides uniform hardness through the full plate thickness. In the market, plate is typically made of mild steel that is surface heat-treated to increase the hardness of the skin, producing a soft core and soft spots that wear plate prematurely.
Buffalo Wire Works engineers have developed a superior punch plate, which is made from exclusive, hot mill-rolled, certified AR steel, according to the company. “We call it ‘Hard Core’ because its thorough hardness will hold up against your toughest abrasion and impact applications,” the company said. “We offer perforated plate in Hard Core, AR500, AR200, AR400, Hardox, high carbon, stainless steel and other alloys in a full range of thicknesses.”
Buffalo Wire Works, www.buffalowire.com
Carrier Vibrating Equipment
Carrier vibrating screeners are designed to screen, scalp, dewater or separate materials using a wide variety of screening media. Ideal for dry or wet screening, Carrier’s vibratory screeners can handle up to 1,500 tph, with many deck design options that deliver maximum efficiency. “Our vibratory screeners can be manufactured to meet your needs, with customizable construction and configuration,” the company said.
Features and benefits of Carrier vibratory screeners:
- Ideally suited for wet or dry screening.
- Capacities range up to 1,500 tph.
- Designed for the highest possible screening efficiency.
- Circular motion for increased screener efficiency.
- Vibratory screener units feature a two-bearing design.
- Easy installation, low maintenance and minimum downtime.
- Economical in initial cost and operation.
Carrier vibratory screeners are also available with elliptical motion drives that can solve difficult screening problems. This motion provides a high rate of travel at the feed end, providing a thin material bed and rapid stratification, which separates the fines quickly. At the discharge end, the material flow is retarded, giving near-size particles additional time to pass the screen. Capacities range up to 500 tph.
Carrier Vibrating Equipment, www.carriervibrating.com
The unique design of the VibroSync motor bridge on CDE’s H-Line horizontal sizing screens ensures the even distribution of power across the full screening area for superior screening and dewatering performance. “Isenmann was the first to bring polyurethane screen media to the global market and our 20-year partnership ensures that your Infinity H-Line horizontal sizing screen includes the original and best,” the company said.
CDE’s Trilogy system for the construction of the screen sidewalls eliminates welds and ensures screening performance is maintained for life. Its new U-Span cross members are built for superior abrasion resistance and are fixed to the screen side walls using huck bolts, eliminating welds and ensuring the longest working life for the Infinity screen.
Conn-Weld Industries, Princeton, W.Va., was founded in 1975 by James D. Connolly. Today, Conn-Weld does business around the world, and is a leading manufacturer of aggregates equipment. Conn-Weld’s experience combined with the latest technology offers engineering solutions for unique needs.
One product Conn-Weld offers is the Incline Style Vibrating Screen. It is available in sizes ranging from 10- x 24-ft. to 4- x 8-ft.
Conn-Weld offers design features such as:
- Single, double, triple and quad decks.
- Circular motion prevents plugging.
- Thin bed depth.
- Trunion mounted for adjustable suspension.
- Spherical roller bearing mechanism.
- External counterweights for adjustable throw and uniform load across bearing.
Deister Machine Co.
Deister Machine Co. Inc. offers the Deister BHM-3824-03T, a three-deck, 8- x 24-ft. washing screen with a triple-shaft vibrating mechanism. Inclined screens with the mechanism located between the decks offer the most economical combination of capacity and mechanical simplicity.
The HM/BHM series machine is able to meet a broad range of customer screening applications and is able to be configured with a wide variety of options to meet customer needs. Inclined screens with the mechanism located between the decks offers the most economical combination of capacity and mechanical simplicity. The HM/BHM utilizes a circular throw and gravity to assist with conveying the screened material.
Deister Machine Co., www.deistermachine.com
ELRUS Aggregate Systems’ inclined vibrating screens maximize flow and coverage for increased production with minimal maintenance and downtime. By focusing on the three essential factors of shaft design – speed, throw and location – ELRUS has developed a screen system that provides efficiency, capacity and gradation control while minimizing vibration transfer to surrounding structures.
ELRUS screen plants feature:
- Hydraulic raise and lower screen, and subframe.
- Repacable feed chute.
- Cantilever overhead conveyor.
- Under-cat-walk screen motor mount.
- Folding blocking legs to accommodate tandem jeep axle.
- Optional full-end tension on bottom and middle decks.
- Adjustable height on overhead conveyor.
- Two or three cross conveyors.
- Angled cross members on carry decks.
- Hydraulic leveling.
Johnson Crushers International (JCI) featured the actual combo screen from the hit television show Gold Rush, as well as guest appearances from cast members from the series at this year’s ConExpo-Con/Agg show. The 6203-32CS combo screen offers high-energy, triple-shaft and multi-angle decks, and is available in multiple configurations. Extensive testing has proven the combo screen to increase performance when efficiency is critical and high capacity is required.
“The combo screen combines the benefits of an incline screen with the performance of a horizontal screen,” said Product Development Manager Ian Pendergrass. “The 6203-32CS combo screen offers up to 25 percent more capacity without increasing the footprint or reducing efficiencies.”
Producers are able to view multiple system layouts and consult with the company’s team of industry experts about solutions to their operational needs.
Johnson Crushers International, www.kpijci.com
McLanahan Corp. introduced the McLanahan MD Vibratory Screen, a compact, high-capacity dry screening unit designed to efficiently and effectively screen many products, including dried sand, quick and burnt lime, limestone and others.
The MD Vibratory Screen provides producers more tph per sq. ft. of screen surface area and handles much larger capacities than conventional screens while occupying the same – or less – floor space. Additionally, it is capable of making multiple product sizes simultaneously as progressively smaller material sizes are separated from deck to deck.
McLanahan MD Vibratory Screens are available in widths ranging from 19-in. (0.05 m) to 78-in. (2 m) with one- to five-screen decks depending upon the application. It is capable of handling feed sizes as large as approximately 3 in. and can make size separations down to approximately 60 mesh.
McLanahan’s design concept for this screen reduces the risk of pegging and blinding, while achieving high capacities due to its ability to make a separation at a given size using a mesh aperture of greater size. To provide an even longer screen life, larger particles are removed by heavier, larger screens, while finer screens see only smaller particles and only a portion of the incoming feed.
With a compact design, minimal maintenance, low power requirements and a product that is totally dust-enclosed, this line of screens provide an efficient and cost-effective setting for any operator.
McLanahan Corp., www.mclanahan.com
Metso is expanding its global manufacturing capacity for rubber screening media used in minerals processing by investing in three new injection presses. The presses will be installed at Metso’s facilities in Australia, India and Sweden by early 2018. The investment will significantly increase Metso’s global rubber screening media manufacturing capacity. The demand for Metso’s screening media has grown in the mining segment after the introduction of 1- x 1-ft. modular screening media, Trellex 305PS, in 2016.
“Uptime and availability mean the world to our customers. A mine can easily consume thousands of screening media modules in a year. During maintenance, the right modules simply have to be at the right place at the right time. With this investment, we can answer our customers’ needs and ensure on-time delivery,” said Claes Larsson, product manager, screening media.
The 1- x 1-ft. (305- x 305-mm) screening media module size is a standard in major mining markets, due to safety and compatibility reasons. Metso made the decision to include the size in its Trellex product range, based on customer demand.
“Complementing our extensive wear parts portfolio with an industry standard such as 1- x 1-ft. screening media is a natural step in strengthening our market-leading position. We are the only supplier able to provide everything that a mine needs in a comminution circuit, from spare and wear parts to equipment and service,” said Jose E. Perez, senior vice president, crushing and screening wears. “With this investment, we expand our manufacturing footprint to be better able to serve our customers efficiently, conveniently, with an eye towards shorter lead times and reduced inventory requirements.”
Screen efficiency is often affected by moisture-induced blinding or moisture in the material being processed. That’s because cold wire mesh becomes easily clogged with a buildup of damp, fine material that causes the screen to blind. Attempting to clean screens with hammers, chains or using expensive specialty slotted screen panels, doesn’t offer a permanent solution.
Damp, fine material tends to stick to cold wire mesh causing continuous buildup, closing the opening in the screen. These same damp particles will not adhere to a warm wire. Low-voltage, Converta-Screen electrical heating equipment from Midwestern Industries heats the wire enough to keep the damp material from adhering to the wire, keeping the screen open and allowing the material to pass through.
Adding moisture can control dusty material that may be a health hazard or cause annoying clouds of airborne particulate. This dampness can clog an unheated screen, but with Converta-Screen Healing equipment the material is processed without interruption.
Converta-Screen Heating is safe and shockproof. All exposed conductors carry only as much voltage as a toy electric train. “By working closely with a Midwestern screening professional, we can help determine the best way to eliminate your moisture-induced blinding. Whether it’s one deck or more, Midwestern’s screen-heating system can improve your screening process,” the company said.
Midwestern Industries, www.midwesternind.com
Either single- or double-crowned decks are the standard for producers using wire cloth on their vibrating screens. Although wire cloth has a low up-front cost, it typically wears out quickly and presents safety and maintenance issues that result in a higher cost over the life of the media.
But producers have been hesitant to try the more cost-effective modular synthetic media option because it would require laborious and potentially costly frame modifications. And what if they were not satisfied with the performance of the modular synthetic option? They would need to reverse the installation process, resulting in more cost and loss of production when reinstalling their crowned deck frame.
Polydeck has developed Kwikdeck, a patent-pending system that enables producers to quickly and easily convert a single or double-crowned deck to modular rubber screen media with absolutely no frame modifications. The entire installation process for each 4-ft. section, takes about 45 minutes and utilizes existing bucker bars and side retention rails. Since the modular screen panels contain no latitudinal steel insert, for non-standard deck widths, the panels can be cut to fit on-site.
The Kwikdeck system gives producers who currently use wire cloth an opportunity to try modular synthetic screen media with absolutely no risk if they are not pleased with its performance. The Kwikdeck system can be removed, the bucker bar rubber and wire cloth reinstalled and the deck is back to its original condition. And some producers will appreciate the versatility the Kwikdeck system will give them by providing a longer wearing screening option on an as-needed basis.
Sandvik Construction offers the new QA335 Doublescreen. Featuring a patented technology that gives you ultimate screening flexibility, this new mid-sized unit offers a highly efficient, versatile and productive solution designed with your needs in mind.
Based around a 13- x 5-ft. Doublescreen, the new QA335 includes many features for ease of operation and high levels of efficiency. These include a user-friendly electrical control system with sequential start up, hydraulic screen separation to aid screen media changes and a fuel efficient 74.5-kW/100-hp engine.
The QA335 has been designed with wrap-around walkways to provide a safe working platform for service and maintenance with these being hydraulically operated enabling quick set-up times. The QA335 also features radio control with two-speed tracking for ease of maneuverability on site, and an oil cooler fitted as standard.
The innovative Doublescreen technology is one of the most adaptable and flexible screening solutions available on the market today, the company said. It consists of two high-velocity screen boxes featuring independent screen drives with the ability to adjust the working angle of each screen independently to each other to suit the exact requirements of the application. This offers greater adjustability, increased accuracy and higher screening efficiency, which makes it ideal for producing tight specification products, without compromising on production.
Superior Industries Inc. released the Anthem Inclined Screen, a unit engineered with a single- or double-shaft drive depending on the specific application needs of the bulk-processing customer.
According to Superior, several features will distinguish the Anthem Inclined Screen as a particularly unique solution. First, patent-pending bottle jack lifting points simplify and speed spring replacement and improve safety. Also, a unique segmented belt guard requires only one person to remove and return the guards during maintenance. Screens can be custom designed to fit a customer’s existing structure.
“In my opinion, one of the most unique features is our one style shaft design for all models of our inclined screen,” said John Garrison, vice president of sales at Superior. “Typically, inclined screen shafts are custom machined to the weight of a specific unit, which creates long lead times for replacement parts. To create an eccentric offset on the Anthem Screen, owners and operators simply bolt on weights.”
Superior designs and manufactures its new Anthem Inclined Screen in double-, triple- and quad-deck configurations for 5- × 16-ft., 6- × 16-ft., 6- × 20-ft., 7- × 20-ft., 8- × 20-ft. and 8- × 24-ft. models.
Superior Industries, www.superior-ind.com
Tandem Products (RhinoHyde Products)
Engineered to provide superior wear life when compared to wire cloth, RhinoGrid Hook Screens are manufactured with a tough woven wire support grid so they will not “stretch” like competitive screens, the company said. RhinoGrid has proven to last seven to nine times longer than wire cloth, according to the company.
It also features:
- Unique design reduces plugging.
- Installs just like wire. No conversion costs, no additional hardware.
- Rugged enough to handle heavy loads, wet or dry.
- Decreases noise.
- No “blocking” out of material for bucker bars required.
- Available in side or end tension hooks.
RhinoGrid hook screens are available in many opening sizes from 0.65-mm slotted to 4-in. square openings. Choice of material is dependent on the application and the company has various materials to fit specific requirements. Manufacturing materials are specially formulated to meet the rigorous environmental and application requirements inherent in screening aggregate products.
RhinoHyde Products, www.rhinohydeproducts.com
Telsmith offers a full line of vibrating equipment with models specifically designed to serve industries ranging from 24-hour mining operations, to heavy duty aggregate processing and sizing, to recycling asphalt and concrete products. Products include grizzly and pan feeders, inclined screens, horizontal screens and inclined vibrating grizzly screens. Telsmith vibrating equipment excels at providing advanced technologies combined with outstanding product support.
The company offers:
- Expertise. Application engineers listen to you and help develop solutions that work. With a complete line of vibrating equipment Telsmith can work with you to find the ideal equipment to fit your needs.
- Innovative Solutions. Utilizing modern design tools, Telsmith engineers develop reliable equipment with unique cost saving features. From the development of the Never-Wear sealing system that reduces maintenance and operating costs to the creation of custom deck designs that accommodate unique screen media and improve screen efficiency, Telsmith engineers deliver innovation that works.
- Quality. Manufacturing craftsmen combine the discipline of an ISO 9001: 2008 environment with precision CNC machining and the skill of dedicated master welders. All Telsmith equipment goes through rigorous testing prior to shipping to ensure it measures up to the Telsmith standard.
- Parts Availability. Large stock parts inventories and people who know the machines are in place to ensure a quick turnaround. Telsmith Parts will work with customers 24 hours a day, seven days a week.
- Field Service. On-site service comes from a team of technical specialists ready to respond to a downtime emergency worldwide. Trained Telsmith service specialists are placed in strategic locations to provide prompt response with less travel time.
- Training. Telsmith offers several seminars geared at educating customer staff on equipment for optimum performance. Separate seminar sessions are held for equipment maintenance and plant operations giving customers the opportunity to focus on their interests.
Terex Washing Systems
At a new state-of-the-art Collards recycled-aggregate washing plant in Eversley, Hampshire, England, Terex Washing Systems (TWS) incorporates the very latest technology to enhance quality and efficiency. The AggreSand incorporates a 16- x 5-ft., three-deck screen producing clean 50 mm and oversize for subsequent crushing and delivering the mid and bottom deck outputs to its partnering AggreScrub 150 for subsequent attrition and sizing.
The feed material contains high root content, which is effectively removed by the AggreScrub. The flotation capabilities of the AggreScrub are ideal for addressing the variable contaminants found in recycled aggregate sources such as paper, wood and light plastics. These contaminants together with most of the water and liberated sand particles are passed from the rear of the AggreScrub to the integrated trash screen. This step recovers the lightweight contaminants as a waste and allows the water and sand to be collected.
In addition to flotation, the AggreScrub’s other key purpose is heavy attrition to liberate adherent clays, producing clean organic-free aggregates for a wide range of construction requirements. A 12- x 5-ft. part-rinser integrated within the AggreScrub modular chassis provides the final product splits requested by Collards.
Underflows from the trash screen and the aggregate sizing screen are collected and pumped back to the AggreSand to recover any saleable fine material and ensure maximum efficiency of water management.
Terex Washing Systems, www.terex.com/washing-systems
Unified’s proprietary and patented Flowmax Modular Screening System is extremely adaptable. This system can be a permanent flat deck or modular (removable) solution using modular tension mats. The universal, patented fastening method provides substantial locking area.
Benefits of Flowmax Polyurethane are:
- Longer life – can last 15 to 20 times the life of wire cloth.
- Reduced plugging and blinding; better production performance.
- Variety of materials available; ethers, esters at 60A – 90A durometer.
- Easy installation.
- Flexible installation options.
Flowmax modules allow replacement of worn areas without replacing the entire screen. Modules are available in 12- x 24-in. or 12- x 12-in. panels, giving you the best use of available area plus optimum efficiency in replacement and maintenance.
No matter which installation option you choose, Flowmax offers a universal, patented fastening method, providing substantial locking area. There are no pins, plugs or other loose parts required. Modules are interchangeable between a permanent and removable frame system.
Unified Screening, www.unifiedscreening.com
The Trio TIO Series screen range is designed for continuous operation in the most demanding wet and dry applications. TIO screens are available in 2-, 3- and 4-deck configurations with a feed acceptance size up to 8 in. Screen-support decks can be supplied to accommodate all media types including woven wire mesh, urethane, rubber mats, self-cleaning mesh and punch plate. These screens are oil lubricated and the operating angles can vary from 15 to 20 degrees depending on the velocity required for stratification.
Key features/benefits include:
- The stroke or amplitude is simple to adjust with counterweights that are bolted to the flywheels.
- The vibrating units are attached with threaded bolts for easy servicing.
- Trio uses advanced materials and manufacturing processes to improve service life of critical components and lower maintenance and operating costs.
The TIO screen range is designed for stationary and mobile operations in secondary and finish sizing applications. These screens can be used for both wet and dry continuous-duty operating scenarios. For use in aggregate processing, mining and industrial minerals screening applications, environmental mitigation and recycling separation processes.