SCREENING
anti-blinding technology and long lifespan equivalent of Derrick’ s Polyweb ® surfaces. In some conditions, they could even surpass them- making it possible for American Silica to screen materials previously considered difficult, or even impossible.
When compared to the legacy Linear Motion Machine, the DP815 with Trilogy Pyramid Screen technology is showing the ability to comfortably handle 30 % more solids at feed rates up to 85 t / h and produce solids that are 3 % drier. This improvement translates directly into increased plant throughput and more efficient moisture removal, reducing both handling and drying costs. For American Silica, that means more saleable product per operating hour and lower energy consumption per tonne produced. Derrick’ s DP815 also features a unique screen compression system that allows for screen panel changes in under one minute and compression forces of 14,234N per panel, helping American Silica minimise downtime and labour cost on the machine.
An elegant solution with SuperStacks for Kropz phosphate plant
Phosphate and potash producers have relied on Derrick’ s fine screening technology for decades. Derrick says its equipment’ s high capacity and smaller footprint reduce installation and infrastructure costs while increasing product recovery and grade. Issues with existing machinery and customer dissatisfaction regarding the quality of the product led to the shutdown of the Kropz phosphate plant in South Africa after only a few years of operation. Fluidised bed separators( FBS) had been used, which were unsuitable to produce efficient and consistent classification. Kropz approached Derrick to optimise the grinding circuit’ s performance and improve the recovery and classification of phosphate particles.
The first challenge was identifying the needs of Kropz and understanding how their existing closed grinding circuit featuring FBS and coarse particle flotation technology failed to produce the product with necessary specifications. Derrick assisted in conducting full-scale lab test work to establish a performance baseline of their grinding circuit and to pinpoint the accurate Derrick equipment solution.
Following the full-scale lab testing, Derrick identified the SuperStack ® as the proper solution for Kropz’ s phosphate plant needs.“ The unrivalled capacity and performance of the SuperStack would answer for product classification and customer quality assurance. At the same time, the equipment’ s reduced footprint and low power consumption would save on short-term infrastructure expenditure and
24 long-term operating costs for Kropz, leading to low total cost of ownership.”
Derrick says its proposed solution simplified the plant flowsheet and assisted in achieving Kropz’ s carbon emissions reduction goals, while producing higher quality phosphate to meet customer needs. Kropz ordered four high capacity 390 micron Derrick SuperStack screens, as opposed to more than double the units suggested by a Chinese competitor, saving millions in infrastructure and commissioning costs.“ With lower operating expenditures and a generous payback schedule, Kropz could recommission a derelict plant with top of the line technology built to withstand the harshest environments.”
“ The four SuperStacks offer an elegant and cost-optimised solution to increasing throughput of the milling circuit and top-size presentation to the flotation circuit. We look forward to recommissioning the plant and working together with Derrick to maximise overall efficiencies,” said Michelle Lawrence, COO of Kropz South Africa.
Haver’ s new Autonomous Screening System plus TY-DECK ® NEON
Another advancement in screen monitoring is the new Autonomous Screening System which integrates TSA’ s SOPPI( Image-Based Screening Productivity Optimisation System) with Haver & Boecker Niagara’ s Pulse Condition Monitoring to maximise vibrating screen productivity while maintaining product quality and equipment integrity. SOPPI uses intelligent cameras and onboard image processing to continuously monitor the fines content in the oversize discharge, automatically adjusting feed rate and screen speed through the control system. In parallel, Pulse CM provides real-time structural condition monitoring through sensors installed on both the vibrating body and drive assembly, evaluating parameters such as vibration, acceleration, and temperature. The integration of both systems enables process optimisation decisions to be validated against the dynamic condition of the equipment, ensuring operation within safe limits. This combined approach delivers increased productivity, improved process stability, reduced operator exposure to repetitive monitoring activities, extended asset life, and more effective maintenance planning. By combining process intelligence with equipment health monitoring, the solution creates a framework for autonomous screening operation, capable of continuously balancing performance, product quality, and equipment reliability.
On screening media, Haver & Boecker Niagara’ s TY-DECK ® NEON introduces a simple yet effective approach to screen media maintenance by making screen wear visually identifiable during inspections. Using neon-coloured wear indicators embedded within the screen media, maintenance teams can quickly determine which modules have reached the end of their useful life and which can remain in service. The technology helps operations maximise module utilisation, reduce premature replacements, and improve maintenance planning. During inspections, exposed neon areas highlight wear patterns, enabling faster identification of modules requiring attention and supporting more targeted replacement strategies. This allows shutdowns to be planned more effectively, reduces intervention time, and helps maintenance decisions be based on actual screen condition rather than estimates. By extending usable screen media life, reducing waste, and improving resource utilisation, TY-DECK NEON offers mining operations a practical solution for increasing maintenance efficiency and lowering total screening costs.
Haver’ s new Autonomous Screening System maximises vibrating screen productivity while maintaining product quality and equipment integrity
International Mining | OCTOBER 2026