Several mining and aggregates surgeries have used traditional products, such as woven wire fabric, for years with good benefits, but for surgeries experiencing high wear and regular screen change outs, it’s well worth looking into engineered display media.
Materials such as polyurethane, rubber and perforated steel plates frequently handle heavy and abrasive materials better than woven wire, but operators need to know how to select the very best screen media due to their performance.
The distinction between using “good-enough” display media instead of the “optimal” display media to get the program could be undesirable downtime and expense. WPE Process Equipment offer a wide range of high frequency screens equipment in Australia. Think about three matters when selecting the very best engineered display media for an application.
The perfect display media saves money.
First, look at all elements of an aggregates or mining operation and any obstacles to increasing production rates and profitability. Second, examine the composition of the material going through the vibrating screen and consult a specialist from a reputable organisation to match the best display media to the program, and finally, learn to properly install and take care of the screen press.
Have a Look Around
The very first step toward choosing the most productive display media involves answering several questions. What stuff is being refined? Is the display media reaching the right lifespan for your performance? And what type of struggles are occurring with the current screen press? Consider the types of stuff going on the vibrating screen. Factors like material size, weight and abrasiveness all come into play during the selection procedure.
For instance, screening gravel usually requires media with greater wearability to handle the material’s abrasiveness. On the flip side, substances with high-quality sizes as large as 10 inches require more durable screens due to the constant high results.
Then look at the vibrating display itself and complete a vibration evaluation. Some research systems have been designed to safely monitor logon display performance in real time and detect irregularities before small problems lead to diminished performance or larger problems. In some instances, the machine could be functioning perfectly, but shifting the display media can prevent screening irregularities and the subsequent damage.
Consider the three phases substance goes through inside the vibrating screen, from layered to basic to sharp. Producers can customise the screen deck with numerous types of display media through every phase by accounting for the accessible area and use life to maximise productivity in each phase.
In the layered stage, as the substance of all shapes strikes the screen deck, the media should deal with a deep bed thickness, higher efficiency and a mixture of coarse and fine particles. Fabric should stratify at the centre of the deck through the basic phase, and also near-size and oversize particles ought to be at the peak of the material being screened. Almost all undersize material should have fallen through the display media from the time it reaches the sharp stage at the release, in which near-size and oversize particles should maintain direct contact with the media.
A vibrating screen operator should also examine wearability to ascertain whether media from the 3 phases is reaching maximum possible. If it seems like screen media has to be changed too frequently, think about switching to something stronger.
Then look at the screening challenges. Examine discarded screen media for signals of problem areas, including broken wires, and premature wear as a result of heavy material along with large quantities of illegal fines. Screening problems can cause carryover or contamination, leading to unwanted material from the screened pile, or the added cost of rescreening. Moreover, broken displays mean expensive unscheduled changeouts. All these signs indicate there is probably a much better display media choice for a minimum of one stage of viewing, if not all three.
A Lot to pick From
Manufacturers produce engineered screen media out of several diverse kinds of substances, such as rubber, polyurethane and hexagonal plates. Polyurethane offers a very long lifespan and durability. Look for a polyurethane display media maker who blends their very own stuff and who pours their polyurethane accessible cast instead of injection-molded. The open-source procedure takes about 9 hours to finish and lasts approximately 1.5 to 2 times longer than injection-molded products. Additionally, open cast polyurethane permanently hardens when cured to maintain its chemical properties, so it resists tear and wears. Injection-molded screens, though faster to manufacture, can soften if the temperature rises during screening, leading to less wear life.
Engineered screen media is designed with thicker material for greater durability, but this results in less open location. This is ideal for viewing many tiny aggregates materials or to get decks using mixed media. Hybrid displays are an option that unites woven cable with polyurethane to attain open place closer to wire cloth but with four to six times more wear life when less than woven cable. Other polyurethane screens achieve extra durability using thicker wire to maintain heavy bed depths, big leading sizes and wide bar railing spacing. There are myths which polyurethane is strictly for sensitive programs, whereas there are several others it is only for wet applications; in reality, it functions nicely in both.
Start looking for rubber display media when screening cloth using a top size bigger than 12 inches, or whenever an application demands an opening bigger than 4 inches. Manufacturers can create rubber displays thicker than polyurethane for increased durability. The displays also dramatically decrease sound, handle high-impact applications and withstand abrasion.
Consider perforated metal plates for heavy-duty operations that call for a lot of open areas. Some producers customise every single plate’s thickness to your client’s application and can produce just about any size opening. The screens should be manufactured with tapered openings to resist pegging. Many perforated plates come in different abrasion-resistance degrees, so be sure to pick a plate appropriate for the application.
Get the Best Choice
In case an operations boss finds traditional screen media isn’t functioning and unscheduled change outs are eating into profits, it might be time to contemplate a polyurethane, rubber or even perforated tubing product. Engineered screen media has the advantage of being flexible when bringing enhanced durability and endurance to a vast assortment of software.
Perhaps above all, start looking for a business which takes pride in its function and provides great service and has ethics. That, too, will save you money and time. Following these ideas will enhance an operation’s display media life, satisfaction and profits for many years to come.