Increasingly, aggregate producers are trying to gain efficiencies from their screening equipment while improving product quality. This equipment represents one of the major cost drivers in a plant, so producers want to find ways to eliminate screen blinding to both improve throughput and ensure that the desired particle size is processed through their plants.

Manufacturers are responding to the demand to optimize the performance of this critical equipment. Above all, there is a big emphasis on customizing screening equipment to the producer's unique production requirements.

This means introducing new media material to mitigate blinding. It also requires maximizing centrifugal force while reinforcing the structure with heavy-duty hardware, and designing the equipment to allow easy access for quick maintenance and adjustments that facilitate operational and product customization. Manufacturers of dewatering screening equipment are just as concerned with quality control and have designed their products to ensure that the producer can count on a target moisture content in the processed material.

EFFICIENCIES IN SCREENING

Intensive Dewatering Screens from Classification & Flotation Systems are designed for efficient dewatering of both fine and coarse particles. Features include high G forces; a modular polyurethane flat deck with a variable angle up to 5 degrees and a variable/adjustable dam; and a heavy-duty, stress-relieved body.

Durability is enhanced by massive tube construction, a stress-relieved tube and screen body, channel frame sideplates and trunnion spring mount. Powered by high-speed vibra motors, the units achieve throughputs of 50 to 400 tph.

The units reportedly have extremely dry discharge and a low moisture percentage to allow maximum recovery with minimal waste. Winter drainage reportedly is achieved in 20 minutes.
Classification and Flotation Systems Inc., (800) 666-0154, cfs.usa@gmail.com, http://www.cfs-web.com
Enter 179

New high-energy vibratory screeners from McCloskey International are triple-deck models that produce four streams of graded material. A cross-conveyor system eliminates spillage and blockages as the four product streams are conveyed to their stockpiles. The addition of a fourth product conveyor comes with a hydraulic folding feature that allows for multiple height and angle options and requires no disassembly for transportation because the conveyer simply folds into its transport position hydraulically.

The screeners have robust construction for processing heavy and oversized materials using a high energy screenbox. These screenboxes maximize the total screen area on each deck and operate with a longer and more powerful vibratory stroke, the company says.
McCloskey International, (877) 876-6635, sales@mccloskeyinternational.com, http://www.mccloskeyinternational.com
Enter 180

Derrick Corp. has introduced its Hi-Cap Dewatering Screen, which is designed to deliver production sands to a superior dryness of 85 to 90% solids by weight at production rates of 300 tph. The screen combines high “G” force linear motion designs and high open area urethane screen surfaces. Nearly half of the more than 62 square feet of screen surface is available on a unit, critical for effective dewatering. The screen is typically fed by a screw classifier product, tank classifier cell feed and large cyclone underflow.
Derrick Corp., (716) 683-9010, info@derrickcorp.com, http://www.derrickcorp.com
Enter 181

The latest innovation from Major Wire Industries Limited is Flex-Thane, a Flex-Mat solution for flat-deck polyurethane and rubber screens. The company says it combines the efficiency of Major Wire's proven Flex-Mat technology with the easy installation of polyurethane and rubber panels to eliminate blinding and pegging problems on flat-surface screen decks. Flex-Thane is comprised of independently vibrating wires, bonded in place with the distinctive lime-green polyurethane strips. The product's modular panels install easily on most common flat-surface screen decks, similar to traditional polyurethane and rubber panels.

Polyurethane and rubber screen media offer abrasion resistance, suitability in wet screening applications and simple screen panel changes. These products, however, often sacrifice production for wear life. Major Wire says Flex-Thane is the exception, especially in wet screening conditions. Because this Flex-Mat product ends blinding and pegging on flat, modular screen decks, producers using these types of screens now realize better throughput, consistent production of spec material and better production numbers, the company reports. It is available in 1 × 1-foot panel sizes, with a variety of locking systems to fit virtually any flat-surface, polyurethane screen deck.
Major Wire Industries, (450) 659-5570; major@majorwire.cc, http://www.majorwire.cc
Enter 182

The KPI-JCI Combo Screen combines the benefits of a horizontal and incline screen. With horizontal and incline screen decks, this screen allows the operator to increase capacity in the same footprint as a comparably sized traditional screen. Various sizes of the screens are available on their own or as part of different portable plant configurations.

The company also offers Horizontal Screen Units with a very low profile for installations where height and additional capacity are critical. In addition to increased portability, these screens provide high G-forces, resulting in less plugging and binding and more consistent material travel speed. The screens are available as double or triple-decks and in scalping, sizing or fine screen versions in sizes from 5 x 14 to 8 × 20.
KPI-JCI, (800) 542-9311, sharonalink@kolbergpioneer.com, http://www.kpijci.com
Enter 183

Polydeck Screen Corp. offers Polydex 12 × 12-inch modular polyurethane screen panels with a hardness range from 70 to 90 durometer, Shore A. The panels are available in square, slotted, VR (zigzag) and SVR (slotted zigzag) designs. Openings range from 60 mesh (250 micron) to 4 inches and the panels are available in traditional pin-style and patented PolySnap fastening systems. Various options are available for integrated surface features such as skid bars; 1-, 2- or 3-inch dams; deflectors and restricted flow bars. These features are molded into the screen panel instead of being glued or screwed on.

The manufacturer also offers Polydex Rubberdex 12- × 24-inch modular rubber screen panels made from specially blended natural or synthetic rubber with hardness from 40 to 90 durometer, Shore A. These panels are available in square, slotted, round, VR (zigzag) and SVR (slotted zigzag) designs. Openings range from ¼ inch to 8 inch and the panels are available in traditional pin-style and PolySnap fastening systems.
Polydeck Screen Corp., (864) 579-4594, info@polydeckscreen.com, http://www.polydeckscreen.com/product.htm
Enter 184

Dur-X-LiveWire screens from Durex Products have four different screen patterns to suit the producer's requirements. Straight wire slot openings are long slot screens with parallel wires, a design that reportedly separates dry or damp material with higher throughput than other screen types and with longer wear life than conventional woven screens. Herringbone style openings are slotted openings formed by parallel and in-phase “crimped” wires that suit situations in which gradation from the raw to the finished product is not critical; this design is intended to keep roots, grass and other stringy debris from clogging the screen surface, the company reports.

Diamond Openings are diamond-shaped openings that screen dry or damp material while reducing blinding, plugging and pegging. Dur-X-Accuslot Openings are alternating wires that form triangular-shaped openings and are configured to deliver accurate sizing with the efficiency of long-slotted opening screens.

All four opening styles provide compression-vulcanized rubber strips that are available in four different sizes to match any application, whether large or fine separation.
Durex Products Inc., (800) 826-6931, solutions@durexproducts.com, http://www.durexproducts.com
Enter 185

The GreyStone Aggre-Washer transports by folding down the feed hopper, removing the blocking and hooking up the tractor trailer. Designed for versatility, the Aggre-Washer line consists of plants that are completely wired and ready to run after plug-in. The unit features manual or hydraulic leveling devices and pillow block bearings on the dewatering screw, and it is suited by off-the-shelf replacement parts.

Cross conveyors can be configured at either 24 or 30 inches wide and are 12 feet long. The reversible cross conveyor allows for distribution of material on both sides of the wash plants.

Screen discharge chutes have A-R plate steel chute liners for maintenance-free service life. The chute design allows operators to discharge each product directly onto radial stacking conveyors. A large feed hopper with a water system ensures maximum production to the screen. The feed hopper also allows material to be converted to slurry prior to entering the screen decks.

Each deck is equipped with spray bars to ensure maximum washing coverage. Valves allow the operator to regulate GPM and customize the washing action of the material. A large work platform with safety railings and toe boards gives the operator a safe area to change screen cloth, adjust spray bars and monitor screen operation.

The Aggre-Washer is designed to accommodate several types of horizontal screens. A producer can use its own screen or GreyStone can provide it. Semi-portables can be equipped with an incline or horizontal screen.

Optional equipment includes a triple-axle assembly for 16-foot screen models and larger, an oversize material blending gate, urethane or Ni-hard wear shoes, an incline screen, a hydraulic jack leveling system, roll-away discharge chutes for semi-portables, cross conveyors, an additional No. 2 starter/start-stop switch, and 30-amp male pin and sleeve plugs.
GreyStone, (888) 346-9274, postmaster@greystoneinc.com, http://www.greystoneinc.com
Enter 186

Sandvik low-noise screening media are made of reinforced, hardwearing rubber or polyurethane for mainly dry or wet applications, respectively. The media are available in tensioned, pretensioned, modular and self-supporting designs as well as various standard thicknesses, aperture shapes, sizes and patterns.

Sandvik modular screening media suit flat, stepped and high-low deck configurations, and various aperture sizes in different areas of the deck. They are available in a wide range of thicknesses and aperture sizes, various lengths and widths, and with square, slotted or round apertures in various and specified patterns.

Pre-tensioned rubber and polyurethane panels for dry and wet primary and intermediate screening on cambered decks also are available. Enclosed in a flat steel bar frame, they are available in a range of thicknesses and aperture sizes, various lengths and widths, and with square, slotted or round apertures in various and specified patterns. They also suit trommel screens.
Sandvik Mining and Construction, (404) 589-3800, http://www.miningandconstruction.sandvik.com/us
Enter 187

One of the latest Metso Minerals mobile screen innovations is the new Lokotrack ST352 track-mounted mobile screen with SmartScreen technology. The unit handles jobs that require high production, fine screening and multiple products.

The IC300 Intelligent Controller controls the startup and shutdown processes and supervises and adjusts the unit automatically for optimum screening results, controlling the feed rate and screen performance. In addition, it carefully monitors all the key functions and components of the unit to ensure longevity and reliability. The automation also may be linked to communicate with other Lokotrack crushing plants and mobile screens.

Heavy-duty construction is designed to provide increased stability and durability. The ST352 is mounted on twin 15.75-inch- (400 mm-) wide hydraulically driven tracks. The screen box has end-to-end crowning and an adjustable screen angle, features reportedly designed for higher production and more efficient separation than similarly sized flat screens.
Metso Minerals Industries, minerals.info@metso.com, http://www.metsominerals.com
Enter 188

Ludowici LVT horizontal or multi-slope (banana) vibrating screens can be supplied in single- or double-deck configurations with flat modular surfaces. The screens are designed for either wet or dry screening. Ludowici Silent Knight Exciters that feature low-noise operation of 72 decibels produce high “G” forces. Features include fully bolted construction, the elimination of all subframe structures, cast polyurethane encapsulated cross-members and direct fixing of modular screen panel system to cross-members.

The manufacturer's CA/CB inclined screens feature a design based around the link-belt range of vibrating screens. Used in the dry sizing of minerals, these screens are inclined or typically sloped at 20 degrees and have a circular-motion vibration that allows efficient stratification and separation of different sizes of material. The screens come in sizes ranging from 3.96 feet wide up to 7.92 feet wide and in lengths ranging from 7.92 feet up to 24.09 feet.
Ludowici/Innovative Screen Technology, (304) 855 7880, enquiry@ludowici.com.au, http://www.ludowici.com.au
Enter 189

Mormak screen plants feature heavy-duty main frames and supporting structural members. Screen sizes vary from 3 × 6 to 7 × 24 feet. Single-deck, double-deck or triple-deck screens are available. Under-screen discharge conveyors are designed for machine output, and reversible cross-discharge conveyors are designed for the operation's requirements. All required flashing is provided to prevent product leaks. An access ladder, walkways, a toe board and hand rails or chains are on three sides of the screen. Screen drive motors are available in left hand or right hand configurations. All required blocking legs are included and axle assemblies are designed to suit the plant weights.
Mormak Equipment Ltd., (250) 542-7350, info@mormak.com, http://www.mormak.com
Enter 190

Terex Simplicity two-bearing inclined screens are designed for heavy-duty scalping, intermediate sizing and finished screening of virtually any material. The Simpli-Flo screen is available in a variety of models, sizes and deck styles from 3- × 6- to 8- × 24-foot in one, two-, three- and four-deck units.

Single-piece, continuously welded decks are Huck fastened to extra-deep corner supports and rugged steel side plates for structural strength racking resistance. Corner supports are full height for extra rigidity in the side plate area.

The manufacturer also offers the Simplicity Triple mechanism, two-bearing-inclined screen, which is designed to handle high-capacity scalping jobs or fine screening. The Triple 140-mm mechanism is an alternative to the 160-mm Dual mechanism, which is limited in speed capabilities due to the large bore bearing. The screens are available in two-, three- and four-deck models in larger sizes from 8 × 20 to 8 × 24 feet.
Terex Simplicity, (989) 288-3121, info@simplicityengineering.com, http:// www.simplicityengineering.com
Enter 191

RhinoWire from Tandem Products incorporates several composite materials into a matrix, a configuration designed to provide a long-lasting screen media. The company says it resists blinding and plugging and installs like wire cloth. The material weighs considerably less than wire and reduces the noise level over typical wire screen cloth. Developed as a replacement for wire screen cloth in both wet and dry applications, it is available in 14 square openings ranging from ⅛ to 1½ inches.
Tandem Products, (800) 533-0509, info@tandemproducts.com, http://www.tandemproducts.com
Enter 192

Combi-Flex Rubber Screen Cloth from Richwood is designed to reduce noise pollution and promote safer work environments by replacing old metal screens with long-lasting Combi-Flex screen cloth. The company also offers Combi-Flex rubber screens made with R2000 rubber formula. High abrasion resistance and a low stretch factor — due to pretensioning — provide superior wear resistance. Combi-Flex Rubber Screen panels reportedly last up to 12 times longer than steel screens. The panels are available in a variety of sizes and relief openings.
Richwood, (800) 237-6951, info@richwood.com, http://www.richwood.com
Enter 193

Schenck Process specializes in matching production rate requirements with physical plant restrictions. The company builds traditional size screens as well as exclusive Widebody designs up to 16 feet wide and 34 feet long with flow rates up to 10,000 tph.
Schenck Process, (800) 558-0184, schenckmining.sales@schenckprocess.us, http://www.schenckprocess.us
Enter 194

Telsmith Inc. recently introduced a Vibro-King TL series line of inclined vibrating screens that replaces the existing Vibro-King and Specmaker screen lines with reported longer service life, reduced maintenance and lower operating costs.

A new TL shaft assembly features a “never-wear” seal design that eliminates the need for contact seals, reducing maintenance and providing longer service life. For greater bearing life, all TL shaft assemblies utilize wide-series bearings and polished shaft bearing journals. A large-diameter shaft casing boosts oil volume to allow lower operating temperatures and fewer oil changes, while minimizing maintenance requirements. Centrifugal force keeps oil away from the seal area and a replaceable snap-in urethane labyrinth seal keeps dust out.

Multiple flat and crowned deck designs are available to allow the machines to work with all screen media types. Also, deck spacing between the top and middle decks has been increased to simplify screen media changes. Both single- and dual-shaft models and sizes ranging from 5 × 14 feet up to 8 × 24 feet are available. Dual-shaft assemblies are belt-timed and reportedly provide longer bearing life with greater load-bearing capability.

The new line is available in both standard and heavy-duty models, with all HD models featuring ½-inch-thick side plates. Spring mounts incorporate a “jacking bracket” for safe, quick maintenance access.

For maximum service life, wide series bearings are standard in all TL vibrator assemblies. Featuring a larger shaft tube, TL vibrator assemblies also incorporate a larger oil volume, extending oil change intervals and allowing the bearings to run cooler.

The screens come equipped with ⅜-inch side plates, oil-level sight gauges, spring pedestals, vibration dampeners, A-R liners and shaft mount reinforcing plates as standard equipment. Added features include extra clearance between the decks for maintenance access and optional ½-inch-thick side plates for heavy-duty applications.

The series also has multiple deck design options that allow it to work with virtually any screen media. Easy access counterweights simplify the adjustment of stroke, allowing fine-tuning.
Telsmith Inc., (262) 242-6600, sales@telsmith.com, http://www.telsmith.com
Enter 195

Astec Mobile Screens' DirectFeed 2516T is a track-mounted, direct-feed screening plant that features a 5- × 16-foot top and bottom deck screen. The unit is designed to handle a top size material feed of 24 inches. It is ideally suited for sizing coarse material and/or pre-screening crushers in recycling, demolition and aggregate applications.

The unit is completely self-contained and can process up to three products with on-board stacking conveyors. The two side conveyors have an adjustable operating angle of 18 to 25 degrees. A large feed hopper can be paired with either a belt feeder or optional apron feeder. The track unit can be fed by excavator or loader.
Astec Mobile Screens, (800) 545-2125, agarza@astecmobilescreens.com, http://www.astecmobilescreens.com
Enter 196

Kolman vibrating screens and grizzlies are designed to pack high screening capacity into a small space without excess weight. This design reportedly permits handling surge loads more effectively than positive eccentric-type screens. Formed plate sidewalls, tubular cross members and structural steel frames are configured for durability, the company reports.

Many sizes are available in single, double- and triple-deck models. Lengths vary in 1-foot increments from 4 to 14 feet (HV Models are 10 to 20 feet) and widths vary in 6-inch increments from 24 to 72 inches. Tandem-screen combinations provide flexibility, and vibrating grizzlies are available for heavy-duty applications.

The Kolman Megascreen reportedly is easy to operate yet remains efficient and durable. One operator can take the Megascreen to the jobsite and single-handedly set it up in minutes. A unique design allows the same operator who loads the top deck to remove the saleable product, or the Megascreen can deposit directly onto a conveyor system.

The unit's top deck is constructed with a 5-degree incline to allow plenty of time and surface area to properly screen a wide variety of materials. Tailings fall to the back and screened material is deposited cleanly on the side opposite that which was loaded. Hopper clogging is eliminated by rapid-fire shaker action.

The company provides shipping straps for towing stability and an automatic locking device to keep the wheels securely in the down position during travel. The automatic- drive belt tension device is located for easy access when adjustments are necessary. All tanks, controls, gauges and engines can be easily reached behind lockable doors. The top and second decks are built in two separate pieces so they can be easily removed. The hydraulic controls and engine controls are within reach of each other for operator convenience, the company notes.
Kolman, (712) 754-4661, info@kolman.com, http://www.kolman.com
Enter 197

Terex Cedarapids horizontal screens feature new deck designs that handle larger feed sizes and heavier loads, the manufacturer reports. The decks have larger support beams, new bracing and new joint construction that eliminate sidewall flex. The designs handle medium scalping and heavy urethane media applications.

The screen's oval stroke action, produced by its triple shaft vibrating mechanism, increases screening efficiency and reduces recirculating loads, boosting production. The oval stroke is plug and blind resistant. In addition, the high G-force stratifies and separates large quantities of materials and allows the screen to operate in normally blinding conditions. Efficient screening also reduces load and wear on crushers.

The operator's ability to fine tune the screen along with its oval-stroke action produces material that meets tight specifications. In addition, the triple-shaft oval stroke is designed to run more smoothly than the jerking action associated with straight stroke two-shaft screens.

Additional features include a lubrication system that runs cooler for maximum gear and bearing life; “sealed for life” O-ring Huck bolt construction; and composite non-wearing seals.

The company offers two-deck and three-deck screens ranging from 4 feet wide by 12 feet long up to 8 feet wide by 20 feet long.

Terex Cedarapids also offers ElJay screens with Oval Stoke Action, which is designed to prevent plugging. The ability to fine tune stroke angle, amplitude and speed adds versatility to meet changing screening conditions.

The oval-stroke design affords operators the ability to change the length and angle of the stroke to best suit their screening needs. The more vertical short stroke provides maximum accuracy for separating fines, while the longer, more horizontal stroke moves coarse materials faster.
Terex Cedarapids, (319) 363-3511, info@cedarapids.com, http://www.cedarapids.com
Enter 198

Rotary screens and combination scrubber screens from McLanahan Corp. are used for the separation and washing of ores, rock, sand and gravel and other material. The screens are supported by heavy-duty trunnion rollers that are carried by two self-aligning, anti-friction spherical roller bearings. The screen cylinder tire bases and sprocket segment bases are machined after frame assembly on a giant lathe setup. Rotary screens are driven by a chain-and-sprocket arrangement that incorporates a segmented driven, sprocket-on-screen cylinder. Power is transmitted from an electric motor through a coupling to a reducer.
McLanahan Corp., (814) 695-9807, sales@mclanahan.com, www.mclanahan.com
Enter 199

The BHST 1616 from Deister Machine Co. is a single-deck, 6-by-16-foot, high-speed vibrating screen configured with a higher G-force and steeper inclination for optimal separation of fine materials.

The manufacturer also offers the BHM 3820, a heavy-duty, three-deck, 8 × 20 inclined washing/rinsing screen with dual vibrating mechanisms and baked epoxy-coated springs. The BHT 2716 is a two-deck, heavy-duty, 7 × 16 inclined washing/rinsing screen; its Type T vibrating mechanism features a positive, elliptical throw action that permits a flatter screen operating angle by controlling material movement on the screen for speed and efficiency, the company reports.

The BFO 2510 is a two-deck, 5- × 10 horizontal vibrating screen designed for use in stationary or portable plants. The BTFM3P 3620 is a three-deck, 6 × 20 triple-shaft horizontal screen that combines the efficiency and low headroom of horizontal screens with oval stroke usually associated with inclined screens. The TFO 1612 D is a single-deck, 6 × 12 dewatering screen that offers increased centrifugal force.
Deister Machine Co. (260) 426-7495, http://www.deistermachine.com
Enter 200