Your behavior appears to be a little unusual. Please verify that you are not a bot.


How to find the right screen media formula

By |  April 8, 2022
Thorough machine inspections are designed to help maximize an operation's productivity and profits. Photo: Haver & Boecker Niagara

Thorough machine inspections are designed to help maximize an operation’s productivity and profits. Photo: Haver & Boecker Niagara

Producing the most tons per hour, ensuring product meets specifications and maximizing screen media wear life can be difficult to achieve using only one type of media.

Finding the perfect balance of high wear and maximum longevity isn’t always an easy task. The feed end may wear out before the discharge end, or using a full deck of a more durable type of screen media may reduce your tonnage.

Many times, the solution is not a single “catch-all” product, but rather an ideal mix of screen media types to ensure all phases of screening work correctly. The process of choosing that mix is best accomplished through careful analysis, an inspection of screen media and the vibrating screen – plus a recommendation from an expert.

Here are a few checkpoints to find the best media for each phase and increase screening productivity.

Vibration analysis

Vibration analysis systems can provide real-time, 24/7 monitoring of machine performance.

The resulting data can help producers spot hard-to-see abnormalities the human eye cannot detect before they become costly, such as a hairline crack in the side plate or a twisting motion that will affect both screening efficiency and equipment wear life. This helps minimize downtime and maintenance costs, improving overall profitability.

Inspection

A visual inspection of the vibrating screen and screen media is necessary to better understand areas for improvement.

The discarded screen media pile is one of the first places to look for problem areas, such as broken wires, wear areas, pegging or blinding. Premature wear often occurs with screen media that can’t handle heavy material or excessive abrasive fines.

Screen media openings should be a focus when looking for wear, including when the square openings in engineered media begin to round. Using media unsuited for the application can result in blinding, pegging or carryover, leading to the added cost and time commitment of rescreening. Additionally, broken screens mean costly, unscheduled change-outs.

Careful selection and the correct blend of screen media can mean thousands of dollars in savings for an aggregate operation. Photo: Haver & Boecker Niagara

Careful selection and the correct blend of screen media can mean thousands of dollars in savings for an aggregate operation. Photo: Haver & Boecker Niagara

Screening phases

Screen media manufacturers can help evaluate how material moves through the three phases of screening – from layered to basic to sharp – to give recommendations on the best screen media for an application.

Producers can then customize the screen deck by choosing screen media that maximizes productivity for each phase by blending the optimal combination of open area and wear life.

Material begins its path down the screen deck during the first phase – layered screening – where screen media should be able to handle a deep bed depth, high impact and a mix of coarse and fine particles. Heavy-duty options, such as those using polyurethane, rubber or perforated plates, can excel in withstanding high top sizes and abrasion.

Screen media with the ideal combination of wear life and open area is best for the next phase – basic screening – where most screening takes place. Hybrid screen media, for example, pairs polyurethane’s durability with open area similar to woven wire, and is often a good choice for the middle of the deck.

Sharp screening takes place at the discharge end and requires maximum open area, allowing any remaining undersized particles to fall through and for near-sized material to pass, preventing contamination. Woven wire or self-cleaning media provide the best open area in this phase.

Screen media selection

Screen media inspections provide the information required to recommend the best type of media for each phase of screening.

A certified screen media representative will work with you to decide what combination of media provides the most efficient solution for each phase. This often means using a blend of different types of screen media to achieve the best combination of wear life and open area.

Implementation

The last step is to start switching out screen media. Changing out one section at a time helps to pinpoint where improvements in performance are being made.

Final thoughts

Careful selection and the correct blend of screen media can mean thousands of dollars in savings for aggregate operations. For best results, work with a reputable screen media manufacturer or certified dealer for informed advice.

Steve Fair is the Tyler engineered media manager at Haver & Boecker Niagara.


Comments are closed