How to choose the right screening media for you

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Selecting the correct screen media involves considering multiple factors beyond just the desired separation size. Operators need to consider the following;

• Separation Accuracy
• Capacity Requirements
• Particle Shape and Moisture Content
• Bed Depth and Screen Deck Inclination
• Screen Motion and Type of Screening Material
• Thickness of Screening Media
• Wet or Dry Screening Conditions

This guide will help you navigate through the various factors to consider, ensuring you make the best choice for your specific needs.

Key Considerations for Selecting Screen Media

The first step in selecting the right screen media is to evaluate your operational needs. Consider the following:

Material Size and Weight: Materials with large top sizes (up to 10 inches) need durable screen media to withstand the heavy impact.

Abrasiveness: Highly abrasive materials, such as granite, require screen media with superior wear resistance.

Material Type: For softer materials like limestone, prioritize screen media with a higher open area to improve throughput and efficiency.

To begin the selection process, consider the general type of screening being done. This will help you narrow down your options. Screening can be broadly categorized into four types:

Coarse Screening (Scalping) – Removal of natural fines from the feed material before crushing. The nature of this application requires an extremely robust screen and screening media.

Multi-Deck Screening – Directing material to multiple crushers requires screens with multiple decks; a free-fall screen may be suitable.

Closed Circuit Screening with Crusher – In this process, the screen manages the circulation of the load by feeding oversize material back into the crusher. This application requires an efficient screening solution to remove undersize particles at the same rate they are created.

Final Product Separation – Ensuring the creation of a quality end product. A precise and accurate screening media with good anti-blinding properties is essential in this type of application especially under challenging conditions.

Screening Phases

Understanding the three phases of material screening—layered, basic, and sharp—is also essential. Each phase has different requirements and challenges. The layered Phase handles the initial impact. A polyurethane screen or heavy-duty punch plate screen media is excellent for this phase due to its durability. Open area at this stage is not the key consideration. The Basic Phase requires a balance approach between the screen media’s wear resistance and open area. The last stage known as the Sharp Phase is where precision screening is key. Using a screen media type that offers a high open area, accurate material separation whilst not compromising on wear life is key, ensuring the last of the fines material does not make its way to the oversize pile.

By customizing your screen decks with various types of screen media tailored to each phase, you can achieve the best combination of wear life and open area.

Screening Costs

Choosing the wrong screen media can lead to increased maintenance costs and downtime. It is essential that operators regularly inspect the screen media for issues such as broken wires, wear spots, and blinding or pegging. Frequent checks and timely replacements can prevent costly downtime and ensure continuous operation. Addressing those identified problem areas proactively can save on rescreening costs and reduce the risk of contamination.

Material Types

The type of material used in screen media impacts performance and durability. Common materials include rubber, polyurethane, and steel.

Rubber screening media are ideal for absorbing impact in coarse screening. Available in various hardness levels they offer impact absorption and long wear life. Softer rubbers are flexible, abrasion-resistant, and less prone to blinding.

Steel woven mesh common for tension screens allow for a high open area and are a cost effective option. Depending on the application and material feed characteristics, they may need to be replace regularly to ensure efficient screening.

Panel Thickness Selection

The thickness of the screen panel affects capacity, accuracy, and wear life. Thinner panel screen media offer high capacity, better accuracy, and less prone to blinding and pegging but the disadvantages include a shorter wear life, leading to more frequent replacements. Thicker panel screening media on the other hand, offer a much longer wear life reducing downtime resulting from the less frequent media replacement but they require a much larger aperture for the same separation thus impacting overall efficiency of the material separation.

Hole Shapes and Patterns

The shape and pattern of the apertures on a screen panel can significantly impact performance. Square holes (In Line and Staggered) are the default choice for normal screening conditions. Their staggered holed pattern prevents fines tracking and are better for screening feed stocks with high fines content. Screen media with a slotted hole pattern (Along and Across Flow) offer higher production capacity but lower accuracy. Slotted media are best for wet screening and dewatering. A round hole aperture screen media is best suited for coarse materials, offering longer wear life but they do suffer from a higher risk of pegging.

SEEK OUT GUIDANCE WITH AN EDGE DISTRIBUTOR

Working with EDGE Innovate partner network can provide valuable insights and ensure you choose the right screen media for your operation. With years of experience, they can help evaluate your specific needs, recommend suitable products, and offer support for installation and maintenance.

Selecting the right screen media for mobile screeners involves a comprehensive evaluation of your operational requirements, the phases of screening, material types, and various technical factors. By considering these aspects, you can significantly enhance the efficiency and longevity of your screening process.

For personalized advice and the best solutions tailored to your specific needs, consult with your local EDGE Innovate distributor. They can provide the expertise and products necessary to ensure your operation’s success.

ABOUT EDGE INNOVATE

EDGE Innovate develops, manufacturers and markets sophisticated technologies for shredding, stacking, screening and sorting of primary and secondary raw materials in production processes and recycling. Our Material handling and recycling range is made up of reliable, durable and cost saving products with a wide range of mobile stockpilers, tracked stackers, tracked and mobile feeders, trommels, slow-speed waste shredders, picking stations, material classifiers, roll-sizers and truck off-loaders. Our product range allows our customers; to shred, screen, separate, stockpile and size a vast array of materials

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