Mining, a crucial component of the industrial sector, apply various technologies to optimize the extraction and processing of minerals. Among these, screens play an indispensable role.

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In this blog post, we'll delve into the crucial role of screens in mining, examining their purposes, the different types available, and the typical challenges encountered during screening, along with potential solutions to these issues.

Primary Functions of Screens

Material Separation

Screens are primarily used for size separation. Raw extracted material contains a mix of different-sized particles. Through screening, these particles are classified into various sizes, streamlining the subsequent processing stages.

This process is crucial for determining which materials are ready for further processing and which need additional crushing or grinding.

Quality Control

The use of screens ensures that only material of the desired size range is passed on for further processing, maintaining the quality and consistency of the final product. This is particularly important in applications where particle size can impact the product's performance or value.

Maximizing Output & Reducing Costs

By quickly and efficiently sorting materials, screens contribute significantly to the overall productivity of the mining operation. They enable faster processing of the valuable material and help in discarding or reprocessing less valuable portions.

Efficient screening reduces the load on downstream processing equipment, which can be expensive to operate and maintain. This can result in a direct reduction in operational costs.

Waste Reduction

Screening helps in reducing waste by separating usable materials from those that are too large or too small for the intended use. This separation can lead to more efficient resource utilization and lower disposal costs.

Different Types of Screens Used in Mining

Vibrating Screens

Description: Employs a vibrating motion to separate materials based on size. It consists of a screen deck which can have multiple layers, allowing for the classification and sorting of particles into different size fractions for further processing or use.

Applications: Ideal for both fine and coarse materials. Used widely in mineral processing for size separation and de-watering.

Trommel Screens

Description: Consist of a rotating drum with screen panels. Material is fed into the drum and is screened as it rotates.

Applications: Common in the screening of larger particles and often used in the initial stages of material processing, such as in gold mining.

Grizzly Screens

Description: A grizzly screen is a rugged type of screen used in mining and heavy-duty processing operations, consisting of parallel metal bars set at a specific distance apart to separate large rocks or ore from finer materials.

Applications: Typically used for pre-screening before primary crushing, removing finer particles from larger chunks.

De-Watering Screens

Description: A de-watering screen is a specialized type of vibrating screen used primarily in mineral processing to remove water from wet or damp materials, facilitating easier handling and processing of minerals. It typically features a downward-inclined design and a high-frequency vibration, which helps in efficiently separating water from the solids and improving the overall moisture content of the final product.

Applications: Common in mineral processing where moisture content needs to be reduced before further processing or final product delivery.

Banana Screens

Description: A banana screen is a multi-sloped, high-capacity vibrating screen designed with varying angles, similar to the shape of a banana, which enhances its screening efficiency.

Applications: It is particularly effective in handling a wide range of material sizes and types, making it suitable for large-scale, high-throughput screening applications in mining and industrial processes.

Common Challenges Faced by Screens in Mining

Wear and Tear

Challenge: Continuous exposure to abrasive materials leads to significant wear and tear.

Solution: Use of wear-resistant materials like high-tensile steel or polyurethane screen panels. Regular maintenance and timely replacement of worn parts can also extend screen life.

Corrosion

Challenge: Exposure to moisture and certain chemicals can lead to corrosion.

Solution: Use of corrosion-resistant materials and coatings, such as stainless steel or special protective paints.

Mechanical Failures

Challenge: Bearings, springs, and other components can fail, leading to downtime.

Solution: Regular inspections and preventative maintenance can catch issues early. Using high-quality, robust components designed for mining applications can also minimize failures.

Plugging and Blinding

Challenge: Plugging occurs when Near-size particles can become lodged in the screen openings, resulting in less area for material to fall through and poorer efficiency.Blinding happens when fine particles stick to the screening surface, often as a result of moisture accumulation, progressively covering and blocking the screen openings.

Solutions for Plugging: There are various potential solutions that can be implemented to mitigate this problem:

- Anti-Plugging Screen Media: Using screen panels with self-cleaning properties, like rubber screens or screens with tapered openings.

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- Increasing the Stroke: The stronger vibratory force generated by increasing the stroke of a screen can help to dislodge stuck particles due to the increased motion.

Note: It is crucial to consult with the manufacturer before making adjustments to the screen's stroke. This consultation helps in understanding if other parameters also need adjustment, assessing the added stress which might reduce the lifespan of the screen and its components, and determining whether the screen is designed to operate effectively under increased stroke conditions.

- Screen Angle Adjustment: Changing the angle of the screen can improve material flow and reduce plugging.

- Wet Screening: In some cases, introducing water to the screening process can help keep materials from plugging the screen openings.

Solutions for Blinding: As with plugging, there are various solutions that can be employed to mitigate blinding that are often similar:

- Screen Material and Design: Polyurethane screens or screens with non-stick surface can help reduce blinding.

- Reducing Moisture Content: Pre-drying the material can help minimize blinding, especially in cases where moisture is causing the problem.

- Regular Maintenance: Regular cleaning and maintenance of screens can prevent long-term issues with plugging and blinding.

Conclusion

In conclusion, screens play an indispensable role in the mining industry, serving a multitude of functions from material separation to quality control. As we have seen, various types of screens, each with their unique design and capabilities, cater to the diverse needs of mining operations, tackling challenges from size segregation to moisture control. However, the efficacy of these screens is not without its challenges. Issues such as wear and tear, plugging, and blinding can significantly impact their performance. Addressing these challenges requires not only a deep understanding of the screening process but also access to high-quality equipment and innovative solutions.

This is where Oreflow emerges as a key player. As leader's in supplying quality Australian-made screening solutions, Oreflow stands at the forefront of innovation and expertise in the mining sector. Their commitment to providing strong and efficient screening solutions is evident in their wide range of products, each designed to meet the rigorous demands of mining operations.

With Oreflow, mining companies have a trusted partner who can help them navigate the complexities of screening processes, ensuring optimal performance and longevity of their screening equipment. In a field where precision and reliability are number-one, Oreflow's Australian-made solutions represent the top level of quality and effectiveness in mining screen technology.

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11 Considerations When Buying Mining Equipment

When it comes to buying the right equipment for your mining operation, there are a number of factors to consider. From your budget to the size of your operation and beyond, it’s important to do the research so you install the equipment that is going to help your operation thrive.

But you’ve likely already considered your budget and the type of equipment you need. To ensure you consider all facets of your mining equipment investment, however, here is a list of 11 considerations to keep in mind.

1. Unit Location

This is, unfortunately, one of the elements that don’t get considered until later in the purchasing process. But when you consider your facility or mining location, the space you have to work with, and the condition of the unit’s future location, you ensure that you buy equipment that properly sized, properly equipped, and able to be installed. Innovative mining equipment is more compact than ever, so it makes it a lot easier to streamline installation.

2. Inclines and Declines

Along with the location of your equipment, you should also consider the topography of your extraction, processing, or final product removal. If there is an incline or decline, you’ll need conveyor belts and vibratory feeders that can handle addition friction and have steadier speeds. Ask for materials that will fit in your specific topography, rather than trying to retrofit something.

3. Screen Sizes and Set-up

Without the right screens, your mining operation would not be able to extract the amount of material you need to turn a profit. While the set-up of your entire feeding and vibratory system matter, the size and set-up of your screens matter most. Particle size can have a significant impact on the flowability of the material, and you should work with a manufacturer that can create a set-up that allows materials to flow smoothly. Work with a manufacturer who is willing to create a custom screen set-up.

4. Feeders and Conveyor Belts

Feeders and conveyor belts are necessary for moving and controlling material flow within a mining operation. Not only do they facilitate efficient operation, but better feeders and higher quality conveyor belt systems can increase processing rates and yields. Choosing feeders and conveyors belts designed specifically for mining uses is critical to ensure a seamless flow.

5. Material Activation

Feeding and activating material is one of the primary functions of many mining processes. Properly controlling material flow ensures that downstream processing equipment receives the correct amount of material at the appropriate rate. An essential part of the material activation process, you need equipment that is not only rugged and able to handle the demanding environment, but dependable and requires little maintenance.

6. Efficiency

Modern mining equipment offers better output than older (or used) models, as well as better rates and yields. The ability for units to extract minerals with less energy per revolution reduces the overall cost of the machinery, which increases your ROI over the long run. On top of that, the use of vibration, in combination with grinding media, significantly increases the number of material impacts per minute, decreasing extraction time and creating a more desirable fractured product. The ability to extract ore and minerals quicker allows units to process material more efficiently than older units, so retention time required to extract material is significantly reduced. When looking for equipment, look at energy per revolution, impacts per minute, extraction time, and so forth.

7. Reliability

It’s a universal truth: some equipment is just less reliable than others. Especially if you’re trying to cut costs or retrofit a mining solution, you may find your mining operations being stalled more often than not. Choosing mining equipment with parts designed specifically for your operation and with exceptional ratings is the best way to get returns on your investment.

8. Moisture and Humidity

Heavy duty, weather resistant equipment is still necessary to extract, transport, and process minerals, ores, and precious metals from soil, sand, and rock. And while not all mining locations or materials have moist environments, some do. Because moisture can impact the effectiveness of your equipment, as well as shorten its lifespan (if not properly maintained), you should consider properly rated equipment.

9. Material Retention

If you’re mining materials that are looser in density or have more a fine-grain texture, you’ll need equipment that isn’t just built for heavier weights and more “solid” objects. This will ensure you retain maximum amounts of your extracted materials, as well as prevent contamination.

10. Worker Safety

Modern mining equipment is exponentially safer than a horse, cart, and pick back in the Gold Rush days, but that doesn’t mean that all equipment is 100% safe. Depending on the materials you’re retrieving and processing, you may have more manpower “on the ground.” Choose equipment that reduces dusting and toxic byproducts, and has safety features like emergency shutoffs and blockage detectors.

11. Manufacturers With Mining Expertise

To get truly exceptional mining equipment that you can trust with your operation, you need to work with a proven mining equipment manufacturer.

For over fifty years, General Kinematics has led the mining, minerals, and aggregate industry in our innovation of vibratory and vibrating process equipment. Our proven track record as mining equipment manufacturers and suppliers can be found in our extensive vibratory installation base of over 40,000 units in 35 countries. GK stands behind all our vibrating mining equipment, with unmatched after-sales service and support throughout our global network.

Browse our selection of mining equipment to find the unit that will best suit your application needs or solve your process challenges.

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