Minerals Processing Engineering Md.

Nuruzzaman
ACCE M2521 B.Sc. Engineering(1st class 1st )
Dept. of ACCE
Size Separation 01747566187
Previous Year Questions [email protected]
M.Sc Eng 2017:
a.Why vibrating screens are important?
b.Give the classification of vibrating screens.
c.Discuss circular motion of screens with proper diagram.
d.Name the various types of screen surface.

M. Eng.2017: same as M.Sc Eng 2017

M.Sc Eng 2016:

𝑐−𝑓
a.Drive a reduced screen efficiency equation. Or, Prove 𝐸 =
𝑐(1−𝑓)
b.With proper diagram explain linear vibration screen.
c.Write the name of other type of screen.

M. Eng.2016: same as M.Sc Eng 2016

M.Sc Eng 2015:

a.What are the factors that affect the screen performance?
b.Discuss the following factor below-
i.Feed rate
ii. Open area
c.What are the purposes of size separation in mineral industry?

M.Eng 2015: same as M.Sc Eng 2015

 Minerals Processing Engineering Md. Nuruzzaman
B.Sc. Engineering(1st class 1st )
ACCE M2521 Dept. of ACCE
Size Separation 01747566187
[email protected]

1.What do you mean by size separation? What are the purposes of size separation in
mineral industry?
Ans: Size separation: Size separation is a unit operation that involves the separation of a
mixture of various size particles into two or more portions by means of screening surfaces. Size
separation is also known as sieving, sifting, screening. This technique is based on physical
differences b/w the particles such as size, shape and density.
The main purposes of size separation in the minerals industry are:
a. Sizing or classifying: to separate particles by size, usually to provide a downstream
unit process with the particle size range suited to that unit operation.
b. Scalping: to remove the coarsest size fractions in the feed material, usually so that they
can be crushed or removed from the process.
c. Grading: to prepare a number of products within specified size ranges. Examples
include quarrying and iron ore processing, where the final product size is an important
part of the specification.
d. Media recovery: for washing magnetic media from ore in dense medium circuits; or to
retain grinding media inside grinding mills.
e. Dewatering: to drain free moisture from a wet sand slurry.
f. De-sliming or de-dusting: to remove fine material, generally below 0.5 mm, from a wet
or dry feed.
g. Trash removal: usually to remove coarse wood fibers or tramp material from a slurry
stream.

𝒄−𝒇
2.Drive a reduced screen efficiency equation. Or, Prove 𝑬 =
𝒄(𝟏−𝒇)
Ans:An efficiency equation can be calculated from a mass balance across a screen as follows:
Consider a screen (Fig.1) the feed to which is F t h -~. Two products are generated. A coarse
product of C t h -1 overflows from the screen, anda fine product of U t h -1 passes through the
screen.
Let f be the fraction of material above the cut point size in the feed; c be the
fraction of material above the cut point size in the overflow; and u be the
fraction of material above the cut point size in the underflow, f, c, and u
can be determined by sieving a representative sample of each of the fractions
on a laboratory screen of the same aperture size as the industrial screen and
assuming this to be 100% efficient.
The mass balance on the screen is:
𝐹 =𝐶+𝑈 (1)
1

The mass balance of the oversize material is:

𝐹𝑓 = 𝐶𝑐 + 𝑈𝑢 (2)
and the mass balance of the undersize material is:
𝐹(1 − 𝑓) = 𝐶(1 − 𝑐) + 𝑈(1 − 𝑢) (3)
From equation (1) we get
𝑈 =𝐹−𝐶 Fig.1 Mass balance on a screen

𝐶 =𝐹−𝑈
Putting the value of U on equation 3 we get,
𝐹(1 − 𝑓) = 𝐶(1 − 𝑐) + ( 𝐹 − 𝐶)(1 − 𝑢)
Or, 𝐶 − 𝐶𝑐 + 𝐹 − 𝐹𝑢 − 𝐶 + 𝐶𝑢 − 𝐹 + 𝐹𝑓 = 0
Or, 𝐶(1 − 𝑐 − 1 + 𝑢) + 𝐹(1 − 𝑢 − 1 + 𝑓) = 0
Or, 𝐹(𝑓 − 𝑢) = 𝐶(𝑐 − 𝑢)

𝐶 𝑓−𝑢
Or, = (4)
𝐹 𝑐−𝑢

Similarly putting the value of C on equation 3 we get,

𝐹(1 − 𝑓) = (𝐹 − 𝑈)(1 − 𝑐) + 𝑈(1 − 𝑢)
Or, 𝐹 − 𝐹𝑐 − 𝑈 + 𝑈𝑐 + 𝑈 − 𝑈𝑢 − 𝐹 − 𝐹𝑓 = 0
Or, 𝐹(1 − 𝑐 − 1 + 𝑓) + 𝑈(1 − 𝑢 − 1 + 𝑐) = 0
Or, 𝑈(𝑐 − 𝑢) = 𝐹(𝑐 − 𝑓)
𝑈 𝑐−𝑓
Or, = (5)
𝐹 𝑐−𝑢
The recovery of oversize material into the screen overflow is:

𝐶𝑐 𝑐(𝑓−𝑢)
= = (6)
𝐹𝑓 𝑓(𝑐−𝑢)
and the corresponding recovery of undersize material in the screen underflow is
𝑈(1−𝑢) (1−𝑢)(𝑐−𝑓)
= = (7)
𝐹(1−𝑓) (1−𝑓)(𝑐−𝑢)
These two relationships (6) and (7), measure the effectiveness of the screen in separating the
coarse material from the underflow and the fine material from the overflow.
A combined effectiveness, or overall efficiency, E, is then obtained by multiplying the two
equations
together:
𝑐(𝑓−𝑢)(1−𝑢)(𝑐−𝑓)
𝐸= (8)
𝑓(𝑐−𝑢)2 (1−𝑓)
For screens where the aperture and the cut point are similar (and if there are no broken or
deformed apertures), the amount of coarse material in the underflow is usually very low.
A simplification of Equation 8 can be obtained by assuming that it is, in fact, zero (i.e., u = 0),
in which case the formula for fines recovery and that for the overall efficiency both reduce to:
𝑐−𝑓
𝐸= (8)
𝑐(1−𝑓)
This formula is widely used and implies that recovery of the coarse material in the overflow
is 100%.

3.What are the factors that affect the screen performance?

Ans: Following factors are affecting the performance of screen:
i. Particle Size: In its simplest form, the probability of passage for a single spherical particle
size d passing a square aperture with a size x bordered by a wire diameter w in a single event is
given by the Gaudin (1939) equation:
𝑥−𝑑 2
𝑝=( ) (1)
𝑥+𝑤
or given that the fraction of open area fo is defined as x2/(x + w)2:

𝑑
p=fo (1 − )2 (2)
𝑥
The probability of passage for n presentations is calculated by:
𝑝 ∙= (1 − 𝑝)𝑛 (3)
It can be seen that as the particle size approaches that of the aperture, the chance of passage falls
off very rapidly. The overall screening efficiency is markedly reduced by the proportion of
these near-mesh particles. The effect of near-mesh particles is compounded because these
particles tend to “plug” (also termed peg or
blind) the apertures, reducing the available open area. This problem is often found on screens
run in closed circuit with crushers, where a buildup of near-mesh material can occur and
progressively reduces screening efficiency.
ii. Feed Rate: The principle of sieve sizing analysis is to use a low feed mass and a long
screening time to effect an almost complete (perfect) separation. In industrial screening
practice, economics dictate that relatively high feed rates and short particle dwell times on the
screen should be used. At high feed rates, a bed of material is presented to the screen, and fines
must travel to the bottom of the particle bed before they have an opportunity to pass through the
screen surface. The net effect is reduced efficiency. High capacity and high efficiency are often
opposing requirements for any given separation, and a compromise is necessary.
iii. Screen angle: Equation (3) assumes that the particle approaches the aperture perpendicular
to the aperture. If a particle approaches the aperture at a shallow angle, it will “see” a narrower
effective aperture dimension and near-mesh particles are less likely to pass. The slope of the
screening surface affects the angle at which particles are presented to the screen apertures.
Some screens utilize this effect to achieve separations significantly finer than the screen
aperture. For example, sieve bends cut at approximately half the aperture size. Where screening
efficiency is important, horizontal screens are selected. The screen angle also affects the speed
at which particles are conveyed along the screen, and therefore the dwell time on the screen and
the number of opportunities particles have of passing the screen surface. Banana screens
incorporate a variable-angle slope which allows for increased throughput.
iv. Particle Shape: Most granular materials processed on screens are non spherical. While
spherical particles pass with equal probability in any orientation, irregular-shaped near-mesh
particles must orient in an attitude that permits them to pass. Elongated and slabby particles will
present a small cross section for passage in some orientations and a large cross section in others.
The extreme particle shapes therefore have a low screening efficiency: Mica, for instance,
screens poorly on square aperture screens, its flat, plate like crystals tending to “ride” over the
screen apertures.
v. Open Area: The chance of passing through the aperture is proportional to the percentage of
open area in the screen material (Eq. (3)), which is defined as the ratio of the net area of the
apertures to the whole area of the screening surface (Eq. (2)). The smaller the area occupied by
the screen deck construction material, the greater the chance of a particle reaching an aperture.
Open area generally decreases with the fineness of the screen aperture. In order to increase the
open area of a fine screen, very thin and fragile wires or deck construction
must be used. This fragility and the low-throughput capacity are the main reasons for classifiers
replacing screens at fine aperture sizes. Advances in screen design continue to be made and
examples of cyclones being replaced by screens are reported.
vi. Vibration:
Screens are vibrated in order to throw particles off the screening surface so that they can again
be presented to
the screen, and to convey the particles along the screen. The right type of vibration also induces
stratification of
the feed material (Fig.5), which allows the fines to work through the layer of particles to the
screen surface
while causing larger particles to rise to the top. Stratification tends to increase the rate of
passage in the middle section of the screen. The vibration must be sufficient to prevent pegging
and blinding. However, excessive vibration intensity will cause particles to bounce from the
screen deck and be thrown so far from the surface that there are very few effective presentations
to the screen surface. Higher vibration rates can, in general, be used with higher feed rates, as
the deeper bed of material has a “cushioning” effect that inhibits particle bounce.
Vibration can be characterized by the vibration frequency, v cycles per second, and amplitude, a
meters The term “stroke” is commonly used and refers to the peak-to-peak amplitude, or 2a.
Generally, screening at
larger apertures is performed using larger amplitudes and lower frequencies; whereas for fine
apertures,
small amplitudes and high frequencies are preferred. The intensity of vibration is defined by the
vibration g force, Γ:
𝑎(2𝜋𝑣)2
Γ= (4)
9.81
Vibrating screens typically operate with a vibration force of between 3 and 7 times the
gravitational acceleration, or 3_7 G. Vibrations are induced by mechanical exciters driven by
electric motors, or electrical solenoids in the case of high-frequency screens. The power
required is small compared to other unit operations within the concentrator and is
approximately proportional to the loaded mass of the screen.
vii. Moisture
The amount of surface moisture present in the feed has a marked effect on screening efficiency,
as does the presence of clays and other sticky materials. Damp feeds screen poorly as they tend
to agglomerate and “blind” the screen apertures. As a rule, dry screening at less than around 5
mm aperture size must be performed on perfectly material, unless special measures are taken to
prevent blinding. These measures may include using heated decks to break the surface tension
of water between the screen wire and particles, ball-decks (a wire cage containing balls directly
below the screening surface) to impart additional vibration to the underside of the screen cloth,
or the use of non blinding screen cloth weaves. Wet screening allows finer sizes to be processed
efficiently down to 250 μm and less. Adherent fines are washed off large particles, and the
screen is cleaned by
the flow of pulp and additional water sprays.

4. Give the classification of vibrating screens.

Ans: The classification of vibrating screen can be shown as below-
i. Inclined or Circular Motion Screens
ii. Grizzly Screens
iii. Horizontal, Low-Head, or Linear Vibrating Screens
iv. Resonance Screens
v. Dewatering Screens
vi. Banana or Multislope Screens
vii. Modular Screens
viii. Mogensen Sizer
ix. High-Frequency Screens.

5. Write the name of other type of screen.

Ans: Followings are the name of other types of screens-
i. Static Grizzlies
ii. Mogensen Divergators
iii. Trommels
iv. Rotaspiral
v. Bradford Breaker
vi. Roller Screens
vii. Flip-Flow Screen
viii. Circular, Gyratory, or Tumbler Screens
ix. Sieve Bends screens
x. Linear Screen
xi. Pansep Screen
6. Name the various types of screen surface.
Ans: The name of various types of screen can be given by-
i. Bolt-In Screening Surfaces
ii. Tensioned Screening Surfaces
iii. Woven-Wire Cloth
iv. “Self-Cleaning” Wire screen surface
v. Tensioned Rubber and Polyurethane Mats
vi. Modular Wire and Wedge Wire Panels

7. With proper diagram explain linear vibrating screen.

Ans: As shown in fig7.1, they have a horizontal or near horizontal screening surface, and
therefore need less headroom than inclined screens. Horizontal screens must be vibrated with a
linear or an elliptical vibration produced by a double or triple-shaft vibrator. The accuracy of
particle sizing on horizontal screens is superior to that on inclined screens; however, because
gravity does not assist the transport of material along the screen they have lower capacity than
inclined screens. Horizontal screens are used in sizing applications where screening efficiency
is critical, and in drain-and-rinse screens in heavy medium circuits

Fig7.1 Linear vibrating Screen

8. Discuss different types of motions involved in the vibration of screen with proper
diagram.
Or, Discuss following motions in screen vibration: i. Circular motion screen, ii. Linear
vibration screen, iii. Oval motion screen.
Ans:
i.Circular motion screen: When the
shaft of an inclined screen is located precisely at
the screen's centre of gravity, the entire screen
body vibrates with a circular vibration pattern
(Figure 8(a)). Occasionally, the shaft is installed
above or below the centre of gravity as in the
system shown in Figure 8(b). This placement
results in an elliptical motion, slanting forward
at the feed end; a circular motion at the centre;
and an elliptical motion, slanting backwards at the
discharge end. Forward motion at the feed end
serves to move oversize material rapidly out of the
feed zone to keep the bed as thin as possible. This
action facilitates passage of fines which should be
completely removed in the first one-third of the
screen length. As the oversize bed thins down,
near the centre of the screen, the motion gradually
changes to the circular pattern to slow down the
rate of travel of the solids. At the discharge end,
the oversize and remaining near-size materials are
subjected to the increasingly retarding effect of
the backward elliptical motion. This allows the
near-size material more time to find openings in
the screen cloth. Fig.8 Vibration patterns generated by various
exciter designs. (The star represents the location of
ii. Linear-vibration (Double-shaft) screens: A linear the screen's centre of gravity)
vibration is induced by using mechanical exciters
containing matched unbalanced weights rotating in opposite directions on two shafts as shown
in Figure 8(c). Linear stroke screens can be installed on a slope, horizontally or even on a small
up-hill incline. The angle of stroke is typically between 30 and 60 ~ to the screen deck. Linear-
vibration exciters are used on horizontal screens and banana screens.

iii. Oval motion (Triple-shaft) screens: A three-shaft exciter design can be used to generate an
elliptical vibratory motion as shown in Figure 8(d), which can also be used on horizontal and
banana screens. The three shafts are connected by gears and one of the shafts is driven. The
elliptical motion is claimed to offer the efficiency benefit of a linear vibrating screen with the
tumbling action of a circular motion screen. Higher capacities and increased efficiencies are
claimed over eitherlinear or circular motion machines.
9. Discuss the following types of screens: i. Grizzly Screens, ii. Resonance Screens, iii.
Dewatering Screens, iv. Banana or Multislope Screens, v. Modular Screens, vi. Mogensen
Sizer, vii. High-Frequency Screens.
Ans:
i. Grizzly Screens: Very coarse material is usually screened on an inclined screen called a
grizzly screen. Grizzlies are characterized by parallel steel bars or rails (Figure 9.1) set at a
fixed distance apart and installed in line with the flow of ore. The gap between grizzly bars is
usually greater than 50 mm and can be as large as 300 mm, with feed topsize as large as 1 m.
Vibrating grizzlies are usually inclined at an angle of around 20◦ and have a circular-throw
mechanism. The capacity of the largest machines exceeds 5,000 t h-1.
The most common use of grizzlies in mineral processing is for sizing the feed to primary and
secondary crushers. If a crusher has a 100 mm setting, then feed can be passed over a grizzly
with a 100 mm gap in order to reduce the load on the crusher. The bars are typically made from
wear-resistant manganese steel and are usually tapered to create gaps that become wider toward
the discharge end of the screen to prevent rocks from wedging between the bars. Domed or
peaked profiles on the tops of the bars give added wear protection and prevent undersized rocks
from “riding” along the bars and being misplaced.

Fig 9.1 Grizzly screen

ii. Resonance Screens: These is a type of horizontal screen consisting of a screen frame
connected by rubber buffers to a dynamically balanced frame having a natural resonance
frequency which is the same as that of the vibrating screen body. The vibration energy imparted
to the screen frame is stored up in the balancing frame and reimparted to the screen frame
on the return stroke. The energy losses are reduced to a minimum, and the sharp return motion
produced by the resonant action imparts a lively action to the deck and promotes good
screening.

Fig 9.2 Resonance screen

iii. Dewatering Screens: This type of vibrating screen receives a thick slurry feed and produces
a drained sand product. Dewatering screens are often installed with a slight up-hill incline to
ensure that water does not flow over with the product. A thick bed of particles forms, trapping
particles finer than the screen aperture.

Fig9.3 Dewatering screen

iv. Banana or Multislope Screens: Becoming popular in high-tonnage sizing applications

where both efficiency and capacity are important, banana screens (Figure 9.4) typically have a
variable slope of around 40-30◦ at the feed end of the screen, reducing to around 0-15◦in
increments of 3.5-5◦. Banana screens are usually designed with a linear stroke vibrator. The
steep sections of the screen cause the feed material to flow rapidly at the feed end of the screen.
The resulting thin bed of particles stratifies more quickly and therefore has a faster screening
rate for the very fine material than would be possible on a slower moving thick bed. Toward the
discharge end of the screen, the slope decreases to slow down the remaining material, enabling
more efficient screening of the near-size material. The capacity of banana screens is reported to
be up to three or four times that of conventional vibrating screens.

v. Modular Screens: Units such as the Omni Screen (Figure 9.5) consist of two or more
independent screen modules arranged in series, effectively making a large screen from a
number of smaller units. A key advantage of this arrangement is that each screen module can be
separately configured with a unique screen slope, screen surface type, vibration stroke, and
frequency. This allows screening performance to be optimized separately on different sections
of the screen. The individual screen sections. being smaller and lighter, are mechanically more
robust compared with a single screen with an equivalent total area. Modular screens are
frequently installed in a multislope configuration.

Fig 9.5 Modular Screen

vi. Mogensen Sizer: This is a vibrating screen exploiting the principle that particles smaller
than the aperture statistically require a certain number of presentations to the screen in order to
pass. The Mogensen Sizer (Figure 9.6) consists of a system of oscillating and sloping screens of
decreasing aperture size, the smallest of which has a mesh size up to twice the size of the
desired separation size. This arrangement allows particles very much finer than the screen
apertures to pass through quickly while causing larger particles to be rejected by one of the
screen surfaces. A thin layer of particles on each screen surface is maintained, enabling high
capacity such that a particular screening duty can be met with a machine occupying less
floor space than a conventional screen, and blinding and wear are reduced. The units typically
range in size from 0.5 to 3.0 m wide and can contain up to six decks.

Fig 9.6 Mozensen sizer screen

vii. High-Frequency Screens: Efficient screening of fine particles requires a vibration with
small amplitude and high frequency. Frequencies up to 3,600 rpm are used to separate down to
100 μm, compared with vibrating screens for coarser applications that are vibrated at around
700_1,200 rpm. The vibration of the screening surface can be created by electric motors or with
electrical solenoids. In the case of the Tyler H-series (or Hum-mer) screens, the vibrators are
mounted above and connected by rods directly to the screening surface so that energy is not
wasted in vibrating the entire screen body.

Fig 9.7 High frequency screen

10. Discuss about mathematical models involved in screen.

Ans: Screen models aim to predict the size distribution and flow rate of the screen products.
Models in the literature can be classified as:
1. Phenomenological models that incorporate a theory of
the screening process;
2. Empirical models based on empirical data;
3. Numerical models based on computer solutions of
Newtonian mechanics.

1.Phenomenological Models: Phenomenological models are based on the theory of particle

passage through a screening surface. The two dominant theories are probabilistic, treating the
process as a series of probabilistic events, and kinetic, treating the process as one or more
kinetic rate processes. These modeling approaches are comprehensively reviewed by
Napier-Munn et al. (1996) and King (2012). They have been incorporated into simulators that
help guide screen selection and operation.
2. Empirical models based on empirical data : Empirical or capacity models aim to predict
the required area of screen and are frequently used by screen manufacturers. There are a number
of formulations of these models of the general form,
𝑆𝑐𝑟𝑒𝑒𝑛 𝑓𝑒𝑒𝑑 𝑟𝑎𝑡𝑒 (𝑡ℎ−1 )
𝐴𝑟𝑒𝑎 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 =
𝐶 × 𝐹1 × 𝐹2 × 𝐹3 × … … .× 𝐹𝑛
where F1 to Fn are correction factors and C is the base screen capacity in th-1 per unit area when
the other factors are 1.
One set of correction factors: account for the feed size distribution, namely: the quantity of
oversize (material larger than the aperture), half-size (material less than half the aperture size),
and near-size (material between 75% and 125% of the aperture size). Other factors include: the
density of material being screened; whether the screen is a top deck or a lower deck on a
multideck screen; the open area of the screen cloth; whether square or slotted apertures are
used; whether wet-screening is employed; and the desired screening efficiency.
The calculations have been developed for specific screen-types: inclined circular stroke
vibrating screens using standard wire-mesh screen. As there are many other variables, screen
types, and screening surfaces in use, accurate screen selection for a particular application is best
done by seeking advice from equipment suppliers in combination with pilot-scale testing.
Compared to the crusher, the screen is considerably less costly, but failure to size the screen
correctly will mean throughput will not be met.
3. Numerical models based on computer solutions of Newtonian mechanics: Numerical
computer simulations are being increasingly used to model the behavior of particles in various
processing equipment, including screens. It is expected that numerical simulation techniques
such as the Discrete Element Method will gain wider application in the modeling of industrial
screens and assist in the design and optimization of new screening machines.

11.Discuss the types of screening surfaces.

Ans: The types of screen surfaces are discussed below –
1.Bolt-In Screening Surfaces: Screening surfaces for screening duties with particles larger
than around 50 mm frequently consist of large sheets of punched, laser-cut, or plasma-cut steel
plate, often sandwiched with a polyurethane or rubber wear surface to maximize wear life.
These sheets are rigid and are bolted to the screen (Figure 11.1). Curved sections of screens of
this type are also commonly used on trommels. These screening surfaces are available with
custom designed aperture shapes and sizes. Apertures usually have a tapered profile, becoming
wider with depth, thereby reducing the propensity of particles pegging in the aperture.

Fig11.1 Bolt-In Screening Surfaces

2.Tensioned Screening Surfaces: These screen surfaces consist of cloths that are stretched
taut, either between the sides of the screen (cross tensioned) or along the length of the screen
(end tensioned). Maintaining the correct tension in the screen cloth is essential to ensure
screening efficiency and to prevent premature failure of the screening surface. Tensioned
screens are available in various wire weaves as well as polyurethane and rubber mats.
3. Woven-Wire Cloth
Usually constructed from steel or stainless steel, these traditional screen surfaces remain
popular. Wire cloths are the cheapest screening surfaces, have a high open area, and are
comparatively light. The high open area generally allows a screen to be smaller than a screen
with modular panels for the same capacity duty. In relatively light screening duties, therefore,
wire-tensioned screens are often preferred. Increasing the wire thickness increases their
strength, but decreases open area and hence capacity. Various types of square and rectangular
weaves are available. Rectangular screen apertures have a greater open area than square-mesh
screens of the same wire diameter. The wire diameter chosen depends on the nature of the
work and the capacity required. Fine screens can have the same or greater open areas than
coarse screens, but the wires used must be thinner and hence are more fragile.

Fig11.2 Woven wire cloth screen

4 “Self-Cleaning” Wire screens

Traditionally, blinding problems have been countered by using wire with long-slotted apertures
or no cross-wires at all (“piano-wire”), but at the cost of lower screening efficiency. Self-
cleaning wire (Figure 11.4) is a variation on this, having wires that are crimped to form
“apertures”, but individual wires are free to vibrate and therefore have a high resistance to
blinding and pegging. Screening accuracy can be close to that of conventional woven wire
mesh; and they have a longer wear life, justifying their higher initial cost. There are three main
types of selfcleaning weave: diamond, triangle, and wave or zig-zag shaped apertures. The
triangle and diamond weaves give a more efficient separation.

Figure 11.4 “Self-Cleaning” Wire screens

5.Tensioned Rubber and Polyurethane Mats
Interchangeable with tensioned wire cloths, these mats are usually reinforced with internal steel
cables or syntheticcords. Polyurethane and rubber screen decks are popular in harsh screening
duties. They are usually assembled in modules or panels that are fixed onto a subframe
(modular screening). Both materials offer exceptional resistance to abrasion and can have
significantly longer wear life than steel, although the open area is generally lower than wire.
Rubber also has excellent impact resistance; therefore rubber is often used in applications
where top size can be greater than around 50 mm. Polyurethane is generally preferred in wet
screening applications. Aggregate producers prefer tensioned mats because they must be able to
make frequent deck changes to produce different specifications, and tensioned mats are quicker
to replace than modular screening systems. Modular polyurethane and rubber screen panels are
typically 305 mm3305 mm, 610 mm3305 mm, or similar, in size. The edges of the panel
usually contain a rigid steel internal frame to give the panel strength. Panel systems allow for
rapid replacement of the deck. Different panel types and aperture sizes can be installed at
different positions along the screen to address high wear areas and to optimize any given
screening task. Modular screens do not require tensioning and retensioning and damaged
sections of the screen can be replaced in situ. Polyurethane and rubber screens are also quieter,
and the more flexible apertures reduce blinding compared with steel wire cloths. Square,
rectangular, and slot apertures are the most commonly used aperture shapes. Rectangular and
slot apertures can be in-flow (usual for sizing applications), crossflow (usual for dewatering
applications), or diagonal. With slabby particles rectangular and slot apertures provide greater
open area, throughput, resistance to pegging, and efficiency compared with square apertures.
Other aperture shapes include circles, hexagons, octagons, rhomboids, and teardrops.
Combinations of shapes and configurations are also possible. Circular apertures are considered
to give the most accurate cut, but are more prone to pegging. Slotted, teardrop, and more
complex aperture shapes are used where blinding or pegging can be a problem. Apertures are
tapered, being wider at the bottom than the top, to ensure that a particle that has passed through
the aperture at the deck surface can fall freely to undersize.
6. Modular Wire and Wedge Wire Panels
These have much greater open area compared with modular polyurethane screens. These wire
panels consist of a polyurethane or rubber fixing system molded around a woven-wire or
wedge-wire screening surface.