Converting to modular screens

Poly and rubber modular screening systems have been seen as the domain of the mining industry, as opposed to the quarry market space, as the initial capital investment required to convert a deck from cross-tension to modular can often be a deterrent.

However, the long term benefits of modular screening outweigh the initial investment, eg:

? Improved screening efficiency.
? Ability to fine tune panel design across a deck.
? Consistent final product.
? Long wear life.
? Reduced downtime and change over cost.
? OHS benefits.
? Reduced noise levels compared to wire screens or punch plate.

Starting with the critical and practical safety element, poly and rubber modular panels can be easily handled by one person. Modular panels contain no sharp edges, reducing the potential for cuts and grazes, and can be easily manoeuvred around a screen deck, replaced one at a time.

In contrast, cross-tension screens require a minimum of two people to install and, given their size and weight, can be very cumbersome to handle.

{{image2-a:r-w:250}}Regular maintenance and monitoring of the screen deck will identify panels that are wearing, and a modular system allows the site to replace only the worn panels, rather than the entire screen deck.

Therefore, it becomes practical to hold a small number of spare replacement panels for immediate changeover. Unlike cross-tension panels which are large and take up considerable space, spare poly and rubber modular panels can be stacked up, ready for any unscheduled breakdown or maintenance.

Locker Group Mining?s poly and rubber modular screen panels have a longer wear life when compared to cross-tension HTS wire screens, due to special material compounds.

The inherent flexibility within the polyurethane and rubber material means that the product being screened is not constantly hitting a hard/rigid surface causing high wear due to the constant pounding. The polyurethane and rubber works with the vibration of the machine and impact of the material.

As opposed to cross-tensioned decks which camber across the screen deck, Locker?s modular panels are installed flat, reducing the potential for uneven wear across the deck and reducing the likelihood of material being misplaced along the edges of the screen and wear liners.

This design provides an even surface for the feed material to access, and with correctly designed panel openings and profiles, the final product is more consistent in size. The modular screening systems are customer specific, with aperture, opening style, panel profile and thickness all determined and designed to suit the specific customer and site requirements.

Locker Group?s product range is available in modular single and double panels, 305mm square or 300mm square and 610mm x 305mm range of thicknesses, in apertures ranging from 0.1mm to 250mm. Locker Group draws on the extensive experience of an R&D team headed by industry experts.

They are in a unique position to provide site-specific advice on the correct profile shape, panel size and thickness, fixing system and use of accessories.

{{image3-a:l-w:250}}Locker Group poly modular panels are fully injection moulded which ensures accurate openings and consistent construction, panel after panel. This also allows the panels to incorporate features during the panel construction, such as rider bars or cross-dams, so that they form an integral part of the panel, rather than laminated on after production.

This produces a much stronger panel and deck design, without the risk of delaminating.

The ability to custom design both the panel design and screen deck extends to variation of panel design and open area across the deck. Pending the requirements of the site and specifications of the feed material, it may be suitable to fine tune gradations in the panel, one row of panels at a time.

The design of the Locker Group poly modular panels ensures they maximise the open area. The fixing system doesn?t require a thick frame around each panel, hence there are more holes and a higher open area percentage per panel, maximising efficiency, without sacrificing wear life.

One of the major benefits of converting a screen deck to either poly or rubber modular panels is the reduction in pegging and blinding. A screen deck that is suffering from pegging or blinding is, by definition, screening poorly. Although at opposite ends of the spectrum, pegging and blinding produce similar results in terms of the effectiveness of the screen. If these issues are not resolved, and a screen continues to peg or blind, the open area continues to decrease, reducing the screening efficiency.

Pegging occurs when near size material becomes lodged in the screen openings and cannot pass through.  There are a number of features which can be built into the poly modular panel, which will reduce this issue, including:

  • More flexibility within the base material, to allow particles to pass through.
  • An alteration to the design of the panel opening, to include a relief angle.

Resolving the pegging or blinding, utilising poly or rubber modular screening panels, provides excellent screening efficiency and reduces the likelihood of finer materials passing over the top or being misplaced along the screen deck.

Locker Group screening experts will work with individual sites interested in converting across to a poly modular long life system. Locker?s team is able to offer customer specific process and technical support on improving the efficiency of your screening process, and will design a system to suit exacting site requirements.

Source: The Locker Group

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