SCREENING TECHNOLOGY
particular screening challenges and user friendly safety elements in our designs – guarding packages that are easy for the customer to use , that don ’ t rust or rattle and break – all add value to the user . Then there are early warning sensor-based systems under our condition monitoring package , which mines are increasingly expecting and utilising to best effect . But overall , it ’ s about maximising screen efficiency and balancing this with the wear life of the screen media and using everything learned over our 45 year screening journey to deliver the most effective solution for each individual customer .” Interestingly , McKerr said that while the FLSmidth design philosophy doesn ’ t add weight to screens for weight ’ s sake that it is at the heavier end of the market but that this is often appreciated by customers for reliability . “ We use weight where it ’ s needed – we use the right structural member and section sizes to match the design stress limits in order to maximise operational continuity .”
FLSmidth runs detailed FE analyses – considering both stress and natural frequency – which can deliver the soundest structural designs available in today ’ s market . “ If you aren ’ t running at a natural resonance frequency that ’ s one less thing to damage the screen , but getting the frequency plot right isn ’ t something all suppliers look at .”
Market wise he said the usual suspects in commodities are driving screen demand – namely copper , gold , coal and iron ore ; and that customisation by material is where the wear packages really come in to effect . Iron ore can have double the SG of coal so it wears screens out much more quickly and needs a much more robust wear solution using rubber , polyurethane , composite ceramics and extra steel plating . “ In copper , gold and iron ore you can start screening at 300 mm maximum lump size , but in coal you may not start until – 50 mm , again much less wear . You try to design screens for any application then customise wear packages from there .” FLSmidth like several of the other players also makes its own screening media including open cast PU which has been proven to perform better in some mining applications than injection moulded media .
IM
Paul Moore spoke to Kristen Randall , Haver & Boecker Niagara Marketing Manager about its screening range and focus
Q In mining specifically are you seeing demand for larger screens or mainly more customised designs by commodity , or both ? A There is definitely a demand for larger screens in some mining applications . It often depends on the product being screened , the region and customer preference . In the iron ore mines of Australia or South America , for example , we employ our high-capacity XL- Class screens , which can handle up to 15,000 t / h . Many of our mining customers in North America , on the other hand , employ our double-eccentric F-Class inclined screen which maintains consistent g-force and virtually eliminates vibrations into the structure .
Q What models in your range are most used in mining today and has this changed over the years ? A Our F-Class and XL-Class were specifically designed to perform in the mining industry , and have been for many years . The F-Class was first manufactured back in the 1930s , and through advancements in engineering over the years it still performs well today . The XL-Class was originally designed specifically for the iron ore industry and is now used in a variety of applications .
Q How important in today ' s mining screening market are aspects such as noise and vibration reduction and how is Haver & Boecker Niagara addressing this ? A Noise is a concern not only in communities where residents live close to mining operations , but also for the health and safety of miners . We address this in a few ways . Our F-Class vibrating screen , for example , features a double-eccentric shaft assembly and shear rubber mounts which help to virtually eliminate vibrations into the structure and maintain constant g-force during starting and stopping , all of which greatly reduce noise . We also offer polyurethane , rubber and our signature Ty-Wire hybrid screen media options , available in both tensioned and modular panel configurations , which further help to reduce noise compared to woven wire or perforated plate .
Q Equally what about real time screen performance monitoring and adjustment - is that something that is already here or on the horizon ? A Monitoring is definitely already here . Haver & Boecker Niagara has developed two systems to help our customers monitor their screening equipment to help prevent unwanted downtime , catch issues that can lead to catastrophic failures , increase safety , and provide operations with peace of mind .
The first system is Pulse Vibration Analysis , a service that helps our customers achieve production targets , minimise unscheduled downtime and demonstrate sustainable improvements through online asset management . Pulse sensors are installed at dedicated positions on the body of the vibrating screen , where they measure the speed , stroke and amplitude . A Haver & Boecker Niagara service technician reviews the results immediately , and then conducts a complete vibrating screen inspection . A Pulse Diagnostic Report is generated , illustrating the health of the vibrating screen along with the technician ’ s recommendations . The Pulse Diagnostic Report is available in the Pulse Web Portal , where producers can access each of their vibrating screens ’ service and performance history .
In addition to our signature Pulse Vibration Analysis monitoring service that includes a visit by a service technician , Haver & Boecker Niagara ’ s Pulse Condition Monitoring system provides producers with 24 / 7 monitoring of their vibrating screens . Permanent sensors are installed on the vibrating screen to consistently record data , giving producers access to information in real-time and helping to detect problems early to avoid increased operational costs . The system records machine history to help minimise downtime and maximise productivity and profits .
Q And modular screening media – do these have an application in mining ? A Many of our mining customers use modular screen media panels , which are available in polyurethane , rubber and hybrid options . Often a blend of different types of media on a single deck works well , as the combination allows you to achieve the optimum balance between wear life and open area . Modular panels are excellent from a maintenance perspective . If you have a worn 1 x 1 panel , for example , it ’ s a lot easier and more cost-effective to exchange it for a new one , rather than replace an entire screen section .
Q What are the advantages for mining screen customers in mining to source the screen and screen media from the same supplier ? A Haver & Boecker has been manufacturing screen media since the late 1800s and vibrating screens since 1930 . We are experts at looking at the big picture . We engineer and manufacture both vibrating screens and screen media , and we have developed our own diagnostics system , Pulse Vibration Analysis . This gives us the insight to offer valuable advice producers won ’ t find elsewhere .
Haver & Boecker Niagara helps customers through PROcheck , a service program dedicated to keeping screening operations running at peak performance . Each analysis comes complete with a thorough vibrating screen and screen media inspection report — known as a PROcheck — and focuses on recommendations for optimisedscreening . The program is complemented by Haver & Boecker Niagara ’ s Pulse Vibration Analysis to help customers maximise productivity , proficiency and profit .
50 International Mining | OCTOBER 2020