Products and Equipment to Get the Job Done Right.
By Mark S. Kuhar and Josephine Patterson
Screening and washing products are constantly evolving, however the goal stays the same: size product in a fast and efficient manner to push production to higher levels. Here are some of the latest products on the market.
FLEX-MAT vibrating wire screens from MAJOR will provide more spec product at a lower operating cost, while delivering more wear life and eliminating blinding, pegging and clogging issues.
Faster Stratification Process
Vibration is the essential action needed when screening material. It allows coarse material to rise to the top and fine material to fall to the bottom.
When using static screening media (woven cloth, polyurethane or rubber panels, etc.), the only vibration is induced by the screen box, which typically vibrates with a range of 500 to 1,000 strokes per minute. FLEX-MAT High-Vibration wire screens have individual wires that vibrate independently at a high-frequency of between 6,000 to 10,000 strokes per minute.
FLEX-MAT accelerates the stratification process and allows more material to pass through the screen.
Industry-Leading Wire Technology
A wire’s quality plays an essential role in a screening media’s performance. The effective quality of wire depends on the right balance of three factors:
- Hardness – Resistance to abrasion and wear.
- Tensile Strength – Resistance to failure/breakage under stress.
- Ductility – Capacity to support stress and to be formed without breaking or losing its properties.
MAJOR ensures optimum wire quality and consistency at all times by developing, (through its own specifications and internal laboratory quality controls), the best recipe for a wire’s chemical content to optimize all factors, and by using the most advanced patented wire-making process, Major also only uses the highest quality of stainless steel wires with the highest tensile strength, available in Type 304 and Type 316.
Hard or Direct-Drawn Process – This is the basic process to make a wire by having the rod drawn through a conic die to a specific dimension (in one or several sequences).
Oil-Tempered Process – This process is an attempt at improving the molecular structure. The rod is drawn through a conic die, then heated and then oil quenched.
Patented Process – This process is the ultimate way of improving the molecular structure. The rod is heated first and then cooled at a controlled temperature to optimize the molecular structure before being drawn through a conic die.
Greater Open Area
Open area is the surface aperture (opening) of a screening media that allows material, pulled by gravity, to pass through. The greater the open area, the greater the screening capacity.
Open area varies with the screening media type and affects the tonnage or volume of material that can be processed on a screen deck. On screen boxes with multiple decks, the relation of open area and material gradation between the decks is an important efficiency factor that needs to be balanced.
By using the highest quality wires, MAJOR is able to decrease its wire diameters, which increases open area and throughput, while providing superior wear life.
Longer Wear Life
FLEX-MAT High-Vibration wire screens offers longer wear life than woven wire screens and, depending on the application, outlasts polyurethane and rubber media, according to the company. Its flat surface offers 100 percent of surface wear, compared to only the upper “knuckles” of woven screens, which results in the even wear of its wire, maintaining the opening within the given specification for a longer time. However, polyurethane panels lose opening specification after a certain percentage of wear due to the slight “V” shape of the opening.
Longer wear life reduces downtime, and maintenance and replacement costs.
No Blinding, Pegging or Clogging
The action of vibrating wires eliminates blinding, pegging and clogging problems, even with humid material or rainy conditions.
Designed to provide high-performance on all decks for a wide range of materials, FLEX-MAT screens provides the highest-efficiency level of self-cleaning capacity for higher throughput, reduced downtime as well as maintenance and replacement costs.
Conn-Weld screens are designed per application for severe-duty separation. Features include:
- Designed for large particle separation.
- Designed for large tonnage.
- Designed for extremely large top size.
- Heavy-duty modular designed deck support frame for large particle feed.
- Mechanism with outboard counterweights allow for adjustable stroke.
- Oil lubrication.
- Oil reservoirs assure constant bearing lubrication.
- Two part epoxy paint.
- Cardan drive shaft.
- Overload springs for surge loads.
Deister Machine Co.
Deister offers its Model HSM and BHSM double-deck screens, with widths: 3- to 6-ft., and lengths: 6- to 18-ft.
The double-deck HSM has the vibrating mechanism located between the decks. All HS series models utilize proper depth of material bed management in combination with high g-force operation resulting in optimum separation of fine materials.
Steeper inclination (typically 30 degrees) results in a faster rate of particle travel, therefore reducing depth of bed of heavy feed rates. The reduced depth of bed allows the finer particles to work their way toward the openings for sizing.
Higher-than-conventional operating speed combined with sizable amplitude of vibration translate into higher g-forces that quickly stratify the material bed so that effective screening can begin. The high g-forces resist the accumulation of damp fines on the screen wires (blinding).
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.
- Repackable 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.
General Kinematics was given a challenge. A screen for sizing limestone was sitting more than 100 ft. in the air atop a silo. Due to the difficult access point, it needed to be replaced with a reliable screen that did not get jammed or need maintenance often. The inquiring company sent their material to General Kinematics to be tested as well as four General Kinematics competitors.
General Kinematics loves a tough screening challenge. Over the last 60 years of innovations and field experience, General Kinematics developed a finger deck capable of self-relieving sticky materials. The experts in the General Kinematics R&D Lab knew this screen would be a perfect solution.
The lab results proved General Kinematics’s theory that the finger decks would separate the limestone better than a normal punch plate deck over a mesh screen. Due to the softness of the fines mesh, screens tended to jam up. This led GK engineers to design the STM-Screen Two-Mass Vibratory Screen with a large finger screen deck staggered over a smaller finger screen allowing materials to wriggle free in either deck.
The General Kinematics STM-Screen Two-Mass Vibratory Screen was installed on top of the silo and is running smoothly. It has decreased downtime and required fewer trips to the top of the silo. The maintenance team is happy with its new screen and improved processing power.
Haver & Boecker
Haver & Boecker offers the Tyler L-Class vibrating screen for classifying wet or dry material as well as an ideal dewatering method. The compact machine is versatile and easy to maintain, with no timing belts or gears that normally need replacing.
Producers can customize the 6-ft.-wide machine in two lengths, a 16- and 20-ft. length. Primarily mounted horizontally, the L-Class can also be inclined or declined as much as 3 degrees.
The linear L-Class handles up to 400 tph and features a 45-degree mounted double-shaft overhead drive system with direct-mounted motors. Producers can access multiple speed and stroke options by changing the pulleys and plate weights. The application-specific body design offers simplified maintenance with a one-piece removable head and shaft assembly. In addition, unlike most linear-stroke machines, the L-Class does not require timing belts or gears, making maintenance even simpler.
The L-Class is also ideal for separating water from product in dewatering applications. When positioned at a negative incline of about 3 degrees, the vibrating screen’s g-force moves wet material uphill on the screen. Gravity and the natural operation of the equipment help screen out water before the material reaches the discharge end. The thick layer of material on the screen also acts as a filter cake and presses water out, as well as traps fine particles that would be lost in a thin layer screening process.
A series of four new Mobiscreen EVO aggregate classifying plants from Kleemann complements Kleemann’s mobile jaw, impact and cone-crushing plants with easy mobility, flexible application options and high output.
Now being introduced to North America, Kleemann’s four new classifying screens are the track-mounted double-deck classifying screens MS 702i EVO and MS 952i EVO, and the triple-deck classifying screens MS 703i EVO and MS 953i EVO.
The two plant sizes have a screening area in the upper deck of 75 or 102 sq. ft., respectively. As with the crushing plants, the classifying screens with their convenient transport dimensions and short setup times optimize the productivity of contractor crushing operations.
The MS 702i/703i EVO achieves a maximum output of 386 tph and the MS 952i/953i EVO an hourly output of up to 551 tons. An optimized material flow through the plant makes this possible.
It starts with feeding, which, thanks to the generously sized feed hopper, is possible both with a wheel loader as well as an upstream crushing plant. The material on the extra-wide feeding conveyor is conveyed to the screen box. The screening angle of the box can be adapted to the application. An impact plate at the conveyor discharge distributes the material evenly on the screen surface, keeping wear to a minimum and achieving a high output.
Kleemann also puts safety first with Mobiscreen EVO screening plants. These new screening plants are operated by a mobile control panel that can be installed at three different points on the machine, guaranteeing ideal visibility during operation.
All plant functions are started automatically, without each side discharge conveyor having to be activated individually. Data on machine operation can be read off at the operator panel. The plant is moved without jolts thanks to the proportionally activated hydraulic valves.
When interlinked with Mobicat jaw, Mobirex impact, or Mobicone cone crushing plants from the EVO series, whose size and output are tuned to the EVO screening plants, the plants work particularly efficiently and achieve a high output. An emergency-off function enhances safe working conditions.
KPI-JCI/Astec Mobile Screens
KPI-JCI and Astec Mobile Screens continue to expand their modular structure offerings.
KPI-JCI and Astec Mobile Screens offer a complete line of pre-engineered modular crushing, screening, material handling and washing and classifying components for a variety of applications.
The modular systems feature bolt-together design for simple installation, smaller site footprint and easy access for maintenance compared to normal, stick-built systems. These systems are available in 150 to 500 tph system configurations to meet current production needs and allow for incremental growth.
The cost-effective modules are easily transported in standard shipping containers or flatbed trailers for quick reassembly.
Masaba’s Maximum Series Portable Plants combine maximum tph and maximum portability to give maximum profit. Process materials wherever the opportunity exists with Masaba portable plants.
Masaba’s plants require minimal mobilization time, are fast to deploy and fast to tear down. Masaba’s extensive dealer network will work with the customer to create a completely customizable plant to fit their needs, and can design to meet an area’s DOT laws.
Wheeled plants allow utilization of the largest crushing and screening units available. Masaba Maximum Series Portable Plants pair efficiency and productivity with the proven toughness and durability that customers have come to expect of Masaba products, backed by a five-year structural and two-year component warranty.
New sites or operations looking to upgrade their screening capabilities with no rework to existing structures should look no further than McLanahan’s MAX Inclined Vibrating Screens. Producers can be sure they are getting a solution that will give them more uptime, easier maintenance and a safer working environment.
McLanahan MAX Inclined Vibrating Screens can separate coarse feed materials from finer materials and are offered in sizes and configurations ranging from 5- x 16-ft. to 8- x 24-ft. in triple-, double- and single-deck models.
The MAX Inclined Vibrating Screen is designed to be durable for the longest useful wear life and with maximum strength steel to withstand heavy loading. Sideplates are a fully bolted construction that reduces/eliminates crack propagation due to stress riser in the steel caused by welding and provide the ability to quickly replace worn components without cutting. These sideplates also utilize A572 Gr. 50 plate as standard, giving it a 45 percent higher yield strength than traditional A36 plating.
Downtime is costly for screens in minerals processing and aggregates production. Metso’s new hammerless attachment system for screening media provides safer installation, faster removal and maximized uptime.
Metso’s attachment system for its Trellex screening media offers increased productivity and makes media change-outs safer and faster than with traditional systems.
Up until now, the removal of worn-out pin and sleeve screening media modules has been a time-consuming and potentially unsafe undertaking. Metso’s innovative new attachment system improves worker safety during change-outs.
There is no need to use a hammer when installing and removing screening media. The specially developed pins can be screwed into place as well as removed using an impact driver. Accidents that occur when pins that are stuck get torn off by force can be avoided. In addition to improved safety, the new attachment system cuts the change-out time considerably, resulting in higher uptime and productivity.
The new attachment system is currently available as a standard option for Trellex 305PS screening media in the most common build heights and will soon be introduced for additional build heights.
With so many options in the Polydeck family of products, the company can provide a screen media solution that is guaranteed to meet a customer’s needs for product spec, wear life and performance.
All of its polyurethane screen panels and rubber screen panels are made with an injection molding process, ensuring accurate openings and consistent construction-panel after panel. Injection molding also means that surface features (such as dams and skid bars) are not glued or bolted on, but are an integrated part of the panel’s construction.
Value-added Polydeck differences:
- Highest open area in the industry (by combining PipeTop II stringers with Maxi screen panel design).
- Extended wear life – up to 30 percent more than steel media.
- Versatile fastening systems.
- Superior resistance to blinding and pegging.
- Effectively reduces noise by as much as 50 percent over steel media.
- Modular screen panel design is easier to handle, install and remove than traditional screen mats.
Rhino Hyde modular panels are available to fit most existing modular deck systems. Its modular panels are engineered to maximize production and minimize wear.
- Available in single and dual durometer.
- Membrane panels for blinding applications.
- Many square and slotted openings.
- Cost-effective guarantee.
The company said it has replacement panels for almost all current modular systems. RhinoHyde modular panels have been extensively utilized and tested over the past 20 years.
The company’s materials are custom engineered to meet the demanding requirements of aggregate screening. By formulating and blending its own urethane, RhinoHyde is uniquely positioned to offer an excellent wearing, cost-effective product.
Sandvik Mobile Crushers and Screens introduced a new addition to the Sandvik 341 jaw crusher range with the launch of the new Sandvik QJ341+.
The new pre-screen feature on the Sandvik QJ341 provides high amplitude for excellent separation. This enables the removal of a large amount of fines, resulting in greater efficiency, higher productivity and less wear on the crusher.
The Sandvik QJ341+ will therefore be particularly effective in quarrying applications where a high proportion of fines in the feed material are found, as the new pre-screen “screens out” this material prior to entering the crushing chamber. Test results have already demonstrated increased productivity by as much as 30 percent in certain applications.
To complement the pre-screen, the company has designed a new telescopic natural fines conveyor, with a discharge height of 3.1 m (10 ft. 3 in.) to deal with the increased flow of pre-screened material. The dirt chute has been designed with a steeper angle to enable a faster transfer of material, while also increasing the ability to deal with sticky material.
The three-position dirt chute allows all material passing the pre-screen grizzly to be diverted onto either the main conveyor or the natural fines conveyor. In the middle position it allows a screened product to be produced out from the fines conveyor. All of this is done by positioning the three-way chute without removing any media from the pre-screen.
Superior Industries’ patent-pending Guardian Horizontal Screen is a triple-shaft horizontal screen that can be used in a portable plant application or as a stand-alone product in fixed plants.
It is typically used in finer screening applications that are horizontal or not inclined more than 2.5 degrees. The Guardian Horizontal Screen provides you with a screen design that sizes and separates material more accurately and efficiently than an incline screen.
Unique features include bottle jack lifting points for spring replacement, fully enclosed belt guards with integrated tensioning systems, and hinged access doors on side plates to ease access. The unit can be upfitted to an existing plant or manufactured as an entirely new portable screening plant.
Telsmith feeders are available in sizes ranging from 36-in. x 12-ft. up to 72-in. x 34-ft., in a variety of models and configurations. Severe duty (truck dump) models, built to absorb the impact from trucks dumping large stone, incorporate deep side plates and massive wide flange beam cross supports. Standard duty models offer lower profiles and are commonly used in portable-application vibrating feeders with loader or excavator feed. All Telsmith feeders incorporate a heavy-duty vibrator assembly with cast shafts, open housing – flow through oil lubrication, double row spherical roller bearings and precision cut gears.
Adjustable gear timing and bolt on counterweights allow for maximum stroke adjustment (both angle and length) to achieve optimum feed control and consistent production. Solid pan, straight deck and step deck configurations offer additional versatility in feeder design to consistently deliver on the promise of outstanding performance.
Terex Washing Systems
Terex Washing Systems (TWS) globally premiered its new water-management offering, Terex AquaClear, at Hillhead 2018. The range includes clarifying tanks, flocculent dosing systems, filter presses and all associated equipment enabling TWS to offer an end-to-end solution for washing and water management.
TWS has a dedicated technical team to support Terex AquaClear, consisting of a product manager, engineers and applications specialists, together with a new, cutting-edge laboratory specifically designed for material testing and sample pressing. This ensures optimum equipment selection and specification for customers.
Intelligent automation is common throughout TWS’ equipment range and this is particularly relevant to water management systems. The majority of the company’s systems include fully automated control and adjustment of the flocculant dose, according to the amount of suspended solids and settlement time required. This ensures maximum performance even with highly variable feed materials such as recycled sources and eliminates any risk of over-dosage.
Its wide choice of thickener models and formats ensures customers are offered the best solution for individual needs, all with low operational cost and maximum dewatering in mind. Following the thickener, customers have a choice of filter presses, again depending upon individual material characteristics and performance needs.
Unified Screening’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 to 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 chosen, 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.
Weir offers superior wear-resistant screen media systems. Its Enduron and Trio range of screening equipment are suited to a wide range of applications and deliver outstanding performance and reliability.
Combined with its extensive range of screen media, the company offers a comprehensive screening solutions. Its extensive knowledge and commitment to the research and development of screening technology and wear performance compounds ensures that its products are built to last.