How to effectively diagnose screen media problems

Persistent problems with downtime and production quality can be frustrating, time-consuming and costly.

Aggregate operations must work quickly to resolve issues and minimize losses from downtime and repairs. Knowing how to diagnose problems and find the best fixes can expedite the process.

Here are a few things to consider when it comes to common mineral processing challenges.

Pegging, blinding & carryover

Operations regularly face issues with near- or odd-size material causing pegging in screens or fine, sticky material causing blinding in openings. A depleted open area can ultimately result in carryover or contamination of a screened product, making this a costly problem.

The primary solution for these issues is often the choice of screen media. If using woven wire, consider a high-vibration screen media that bonds the wires with polyurethane strips. This setup allows wires to move independently, effectively dislodging pegged or blinded openings, such as when screening material with heavy clay deposits. The extra vibration amplifies overall stratification.

Early breakage

If the scrap pile is growing too quickly, it may be time to consider a new screen media configuration.

Ideally, screen media should complement the three main phases of screening: the feed end, the middle of the deck and the discharge end. Many operations use mixed screen media for optimal results.

Another consideration is if the problems are caused by damaged equipment or improper installation. Proper tension is key for both the performance and longevity of the screen media. Improper tensioning leads to early breakage. Screen tension should be checked weekly to ensure it is correct.

Final thoughts

It can be overwhelming to diagnose screening problems, but partnering with an OEM or local dealer to find the right screening solution can help. Careful thought and selection can improve the bottom line and reduce headaches associated with downtime and lost profit.

Serge Raymond is a product specialist at Major.