Choose & Use Vibratory Screen Separators Choose & Use ... - Zycon

VB-69Ask Orange TMProvides solutionsto process problemsHow ToChoose & UseVibratoryScreenSeparatorsComplete guide toIndustrial Screening Applications®World authority in advancedtechnology for magnetic, vibratoryand metal detection applications.It’s not magic...it’s ERIEZ

HOW TO CHOOSE AND USE VIBRATORY SCREEN SEPARATORSPageIntroduction 3Defining Equipment Terms 3Circular Vibratory Screeners 4Syncro-Sizer® 4Syncro-Sieve 5Material & Process Considerations 5Decks & Screens for Circular Vibratory Screeners 6Screen Selection Guide 8Rectangular Vibratory Screeners 10Mechanical Screeners 12Custom Equipment & Applications 14Contact Eriez 15Ask Orange TM is a collection of process solutioncase studies and how-to reference manualsdesigned to improve understanding and simplifyspecifying sophisticated magnetic, vibratory andmetal detection equipment needed in most processindustries. Most of this equipment requires anunderstanding of its intended use in order todetermine proper application.The “Professor” icon has been developed to help customers identify AskOrange TM material in printed trade publications, company literature and onits web site. The Ask Orange concept and related images are a tribute tothe company’s founder, Orange F. Merwin, and his innovative ideas usingmagnets to remove metal contamination from various process flows.

HOW TO CHOOSE AND USE VIBRATORY SCREEN SEPARATORSScreen separators are used to remove foreign or other unwanted material from productflows. They can classify dry bulk solids ranging from chunks to fine powders. Screenseparators are used to separate solids and liquids in a variety of applications. Eriezprovides a broad range of screeners for both wet and dry product separation. This book,“How to Choose and Use Vibratory Screen Separators” as written, is intended to helpusers select the correct vibratory screener for their particular process.DEFINING EQUIPMENT TERMSCircular Vibratory ScreenersCircular screeners feature a gyratory motion to move wet or dry product down andthrough a series of “decks”, each with its own screen and with its own discharge spout.Depending on the end product, one, two, three or even four decks can be used to attainthe desired degree of fineness. Generally, the gyratory motion is gentler and is ideal formore fragile product. A variety of mesh screens are available for each deck and to meetyour specific need, decks are available in six sizes. Circular screeners are used forprocessing slurries, waste water, minerals, chemicals and other dry or dewateringapplications. These popular screeners separate and size materials ranging in size from 1/4inch (6mm) to 40 mesh.Rectangular Vibratory ScreenersRectangular vibratory screeners are available in a wide variety of sizes and shapes.Recommended screens range from 20 mesh up to 1/2 inch (12mm) size used for scalping.Rectangular vibratory screeners have a totally enclosed patented magnetic drive and canscreen practically any bulk material from micro size to bulky chunks.Mechanical ScreenersThese screeners are relatively simple, rugged vibratory machines designed to handle avariety of bulk material. The screener is a tuned two-mass vibrating system excited by amotor driven eccentric weighted shaft. Corrosion resistant rubber springs transmit theexciting force and can “fine tune” the motion of the trough optimizing the flow rate for aspecific application. Mechanical screeners are available in a wide variety of sizes, shapesand deck types.These screeners will covered in more detail later.Did you know?The term “scalping” refers to the removal of large chunks from atypically smaller bulk material. Scalping removes these piecesearly in the process flow to allow finer screening down stream.3

CIRCULAR VIBRATORY SCREENERSEriez offers two types of circular vibratory screeners...Syncro-Sizer® and Syncro-Sieve®. These high capacity gyratory screeners are designed for high viscosity liquid/solid separation, and wet or dry classification. The separators are easy to use when tuningfor specific feed rate, product and separation requirements. Both models are used withcircular screens mounted in decks which can be used singularly or in multiples.Syncro-Sizer®Eriez’ Syncro-Sizer® is a gyratory screenseparator designed for high capacity separationby size of dry materials, and for wet separationswhen oversize material constitutes a largepercentage of the feed.The Syncro-Sizer separates and sizes materialsfrom 1/4 inch (6mm) to 40 mesh in size.Because of its unique motion, the Syncro-Sizerprovides outstanding accuracy, capacity andoverall efficiency. It is ideal for food, chemical,metallic and nonmetallic mineral, pharmaceutical,abrasive, ceramic, plastic and other processindustries.The adjustable frequency of up to 1450 cyclesper minute and a variable horizontal andvertical stroke are ideally suited for stratifyingthe material in seconds and directing it in acontrolled pattern over the screen face and tothe discharge. Adjusting the dual eccentricweights easily controls the flow pattern ofmaterial over the screen and the speed withwhich it is conveyed to the periphery.The off-the-shelf motor that can be purchasedanywhere and easily installed, is mounted onthe stationary base of the screener. Motor life isincreased because the motor is isolated from themotion generator.4

CIRCULAR VIBRATORY SCREENERSSyncro-SieveEriez’ Syncro-Sieve is an economical, quality fixedrateseparator. Powered by an “off-the-shelf” rotarymotor with an adjustable weight system that can bevaried to increase or decrease product retentiontime, the Syncro-Sieve is ideal for processingslurries, wastewater, minerals, chemicals and otherdry or dewatering applications.Under normal use, the Syncro-Sieve will provideyears of trouble-free operation.Typical Flow Patterns...depending on how theeccentric weights are positioned in your Syncro-Sieve, the flow pattern on the screen deck(s) may bevaried to improve separation. The diagram belowdemonstrates these various patterns. The instructionmanual which accompanies each Eriez Syncro-Sieve describes the method for making theappropriate adjustments.Quickest ExitLongest RetentionMATERIAL & PROCESS CONSIDERATIONSAs is the case with other types of process equipment, more than one type of screener canaccomplish the same task. Each type of screener mentioned above has certain attributesmaking it the preferred equipment for certain applications.In similar applications, circular screeners are slightly more expensive than mechanical orrectangular vibratory screeners. However they tend to be more compact and thorough asthe material is presented repeatedly to the same “hole” as it circles the screening medium.Circular screeners are limited by their total capacity and particle size being screened.Rectangular vibratory screeners can effectively screen many of the same materialstypically run through circular screeners. However these units also perform well in heavydutyapplications. Both rectangular vibratory and mechanical screeners offer greaterscreening surface area enabling them to process higher volumes and larger particle sizes.Mechanical screeners are lower cost, simple units that provide effective screening ofmany bulk materials.5

DECKS AND SCREENS FOR CIRCULAR VIBRATORY SCREENERSCircular Screeners - Components Deck InterchangeabilityCircular screeners are available in sixdifferent sizes to meet process applicationsfrom a trickle of material or tons per hour.Multiple DecksThere is complete interchangeabilitybetween decks. You can use straight frameor collector frame decks as needed to suityour particular application.Anti-blinding Ball DeckIf ball decks are needed to prevent screenblinding, they are available. Slider discsare also available.Single or simultaneous multiple separationscan be obtained by the use of one,two, three and sometimes four decks.Perforated Screen DecksStraight Frame DecksCustom-made decks to meet the preciserequirements of special applications can bequickly provided.The straight frame is designed for usewhere normal volumes of material are tobe discharged from the top of the screen.Discharge SpoutsCollector Frame DecksThe trough-type design quickly gets largevolumes of material off the top of thescreen and conveys it to discharge points.Depending on the application, one to fourdischarge spouts can be mounted on asingle frame. Each additional spout greatlyincreases capacity of the screener.6

DECKS AND SCREENS FOR CIRCULAR VIBRATORY SCREENERSChoice of Table FramesDistribution PanTable Frames ChoiceStandard dishedbottom table frames are available for allsize separators. Slant bottom and doublediverterframes are available for 36 inchthrough 60-inch units at no extra cost.When your material needs to be channeledback to the center of the next screen down,a distribution pan is attached to the bottomof the exisiting overhead frame.Wet Feed DistributionMaximum Screen UsageThe special “Z” ring used on separatorscreens normally eliminates the centersupport ring. There is no guessing aboutwhether or not your screen is properlytensioned, and there are no wires beingpulled away from the center disc becauseof under or over tensioning. The “Z” ringsare sturdy enough to be rescreened butinexpensive enough to be discarded.Center Disc ScreensThe disttribution for wet processes lets theliquid flow through while the solids aredirected outward in a full circle.CoversTight-fitting covers with a gasketedinspection port are available to keepproduct in the unit where it belongs.For extra heavy material where centerscreen support is occasionally necessary,center hold downs to keep the screenproperly tensioned are available.Buffer RingA buffer ring, used mostly in dewateringoperations, is available if your materialneeds to be retained on the screen for alonger period of time before being circle.Did you know?Eriez Magnetics maintains the world’smost complete magnetic and vibratorytesting laboratory. You eliminateguesswork when tests determine whatparticular problems may be involvedwith your products before a separatoris installed in your plant.7

SCREEN SELECTION GUIDETensil Bolt ClothTensil Bolt Cloth ScreenWireOpenMesh Diameter Opening Area(inches) (inches) (%)Tensil Bolt – 16 MeshTensil Bolt – 36 MeshTensil Bolt – 22 MeshTensil Bolt – 120 Mesh14 .009 .0620 76.416 .009 .0535 73.318 .009 .0466 70.220 .009 .0410 67.222 .0075 .0380 69.724 .0075 .0342 67.226 .0075 .0310 64.828 .0075 .0282 62.430 .0065 .0268 64.832 .0065 .0248 62.734 .0065 .0229 60.736 .0065 .0213 58.738 .0065 .0198 56.740 .0065 .0185 54.842 .0055 .0183 59.144 .0055 .0172 57.446 .0055 .0162 55.848 .0055 .0153 54.2Did you know?Screens with thesame size openingsmay not have thesame amount oftotal “open” area.In some cases TensilBolting ClothScreens can provideup to 30% moreopen area thanMarket GradeScreens. The moreopen screen area themore volume can beprocessed. For helpselecting the properscreen type, contact Eriez'Vibratory Sales Department.50 .0055 .0145 52.652 .0055 .0137 51.054 .0055 .0130 49.458 .0045 .0127 54.660 .0045 .0122 53.362 .0045 .0116 51.764 .0045 .0111 50.770 .0037 .0106 54.972 .0037 .0102 53.874 .0037 .0098 52.776 .0037 .0095 51.778 .0037 .0091 50.680 .0037 .0088 49.684 .0035 .0084 49.888 .0035 .0079 47.990 .0035 .0076 47.894 .0035 .0071 45.0105 .0030 .0065 46.9120 .0025 .0058 47.3145 .0022 .0047 46.4165 .0019 .0042 47.1200 .0016 .0034 46.2230 .0014 .0029 46.09

RECTANGULAR (LINEAR) VIBRATORY SCREEN SEPARATORSEriez’ rectangular screeners are power by apatented AC electromagnetic drive thatprovides a simple yet powerful solution todifficult material screening applications. Allof these drives and their operation arecovered in detail in Eriez’ “How to Chooseand Use Vibratory Feeders and Conveyors”manual...download a copy at eriez.com.Rectangular vibratory screeners efficientlyscreen and separate a variety of materials.Eriez recommends screens from 20 mesh to1/2 inch (12mm) size typicallyused for scalping.These screeners, with their totally enclosedpatented magnetic drive, can screenpractically any bulk material from micronsize to bulky chunks. Simple AC controlsoperate the screeners with “watch-like”precision. In addition, you get all the featuresthat for years have made Eriez screeners theleaders in quality and dependability.Model 85B Grizzly tode–lump iron ore.Model 75B Grizzly tode-dust limestone.Eriez has standard and heavy-duty modelsfor most screening applications. Special unitscan be ordered with multiple drives forgreater capacities. A wide variety of standardand special trays are also available.Grizzlies and Special TraysVibratory screeners with grizzly trays areused in scalping or coarse screeningoperations. Screened trays provide greatercontrol than grizzly trays. Screened traysseparate material by size, dedusting ordewatering. Either tray choice coupled withEriez’ AC drives retains the advantages offergentle material handling and accurate controlof feed rates.Model 85B ScreeningTray with perforated deckto remove oversize lumps.Did you know?Eriez’ experience in designing trays for special applications,along with the computerization of vibratoryscreener variables, means that unusual applicationrequirements can be met quickly and economically.10

RECTANGULAR (LINEAR) VIBRATORY SCREEN SEPARATORSModel 52A with a stepped screenmounted on a portable cart.Model 65B Two–deck Screener forseparating clumps and fines from plasticpellets.A two–deck screening feeder discharges oversizeand undersize products to one side while thedesired material flows off the end.Model 70B Vibratory Sand Classifier used inconjunction with wood–fired boiler, to reclaimunburned wood for recirculation through boiler.Screens are used to sift out ash and sand.11

MECHANICAL SCREENERSEriez’ Model HVS Mechanical Screenersare simple, rugged vibrating machinesdesigned to handle a variety of high volumebulk materials screening.The screener is a turned two-mass vibratingsystem excited by a motor-driven eccentricweighted shaft. Corrosion resistant rubbersprings transmit the exciting force and can“fine tune” the motion of the trough tooptimize the flow rate for a specificapplication.Features• Adjustable-angle rubber springs• Low profile - minimum headroom• Flow rates to 100 ft./min. (30 mpm)• Simple, stable variable controller• Separately mounted components for easymaintenance• Low power requirement• Heavy duty constructionThe ability of the specially designedrubber springs to amplify the troughstroke results in low power requirements.Power is provided by a standard threephase,230/460 TEFC 60 Hz motor.Explosion-proof motors are alsoavailable.Accurate control of amplitude can beachieved with an adjustable variablespeed pulley (see Figure 1) or variablefrequency controller. Both are availableas options.A wide variety of trough sizes and typesare available to match the screener tospecific application requirements.Included are troughs and screens of mildsteel and stainless steel; liners ofabrasion-resistant steel, stainless steel,polyethylene, rubber or other materialsas well as grizzly screen decks.These mechanicalscreeners are wellsuited for handlinghigh volumes ofbulk materialsreliably andeconomically.This screener is twomassvibratingsystem, springcoupled, excited bya motor-driveneccentric shaft. Theadjustable-anglerubber springs - eachof which can be removed and replaced inless than two minutes - can also fine tunethe motion of the screen to optimizescreening for specific applications.Model HVSHigh VolumeScreener12The remarkably compact, straight-linedesign of the Model HVS screener presentsan extremely low profile; minimumheadroom is required for installation.

MECHANICAL SCREENERSModel HVS 18 x 48 forsizing rock salt.Model HVS 36 x 96 with overhead drive forscreening chopped fiberglass.Model HVS 42 x 96 forscreening glass cullet.Model EMS2 with 24 x 60 tray to screencontamination from coffee.This Model TMS 30 x 60 screensoversize clumps of ore.Model EMS2 with 36 x 134 tray toscreen sand from scrap aluminum at1100°F.Eriez and Syncro-Sizer are registered trademarks of Eriez Manufacturing Co.13

CUSTOM EQUIPMENT & APPLICATIONSEriez operates the largest Test and Research facility of its kind for developing customequipment to meet the most demanding applications. Contact a product manager todesign the perfect vibratory solution for your specific needs.FOR MORE INFORMATION on circular, rectangular or any mechanical vibratoryseparator or system available for automation, material movement, separation,purification, benefication, reclamation and pollution control, write or call:ERIEZ MAGNETICS WORLD HEADQUARTERS2200 Asbury Road, P.O. Box 10608, Erie, Pennsylvania 16514, U.S.A.800/345-4946 or 814/835-6000Plate MagnetsGrate MagnetsFerrous TrapsMagnetic HumpsSuspended MagnetsMagnetic PulleysMagnetic SweepersDry Magnetic DrumsWet Magnetic DrumsHigh Intensity SeparatorsElectrostatic SeparatorsSuperconducting HGMSRare Earth Magnetic Roll SeparatorsMagnetic FlocculatorsDemagnetizing CoilsMetal DetectorsTube MagnetsEddy Current SeparatorsMagnetic RailsMagnetic RollsSheet FannersLifting MagnetsHolding MagnetsCoolant CleanersMagnetic ConveyorsVibrating ConveyorsMechanical ConveyorsVibratory FeedersVolumatic FeedersBin VibratorsPrecipitator VibratorsScreen SeparatorsNOTES:14

For solutions toyour process problemscontact your nearestEriez representativeand just: Ask Orange.CONTACT ERIEZWith manufacturing plants on five continents and a global network of factorytrainedrepresentatives, getting professional assistance is just a call away.Country Code: Telephone: E-mail:AUSTRALIA ................... 61........3-9305-4099 ....................eriezaus@eriez.com.auCANADA ....................... 01........905-795-0444 .................... eriezcanada@eriez.caCHINA ........................... 86 ........21-5046-2123 ....................... eriez@eriez.com.cnEUROPE ........................ 44........29-208-68501 .............. eriez@eriezeurope.co.ukINDIA ............................ 91........80-845-5381 ............................... emil@emil.co.inJAPAN ........................... 81 ........473-546381 ........................ thomma@eriez.co.jpMEXICO ........................ 52 ........5-565-3855 ................... operaciones@avante.netSOUTH AFRICA ............ 27........11-444-9160 ..................... eriezmag@iafrica.comUNITED STATES ............ 01 ........814-835-6000 ............................ eriez@eriez.com©2004 ERIEZ MAGNETICS ALL RIGHTS RESERVED0104-5M-AH-PC

World authority in advanced technology for magnetic,vibratory and metal detection applicationsEriez manufactures magnetic lift and separation, metal detection, materialsfeeding, screening, conveying and controlling equipment for application inthe process, metal working, packaging, recycling, mining, aggregate andtextile industries among others. Eriez manufactures and markets theseproducts through nine international facilities located on five continents...Australia, Brazil, Canada, China, England, India, Japan, Mexico, South Africa,as well as the United States.0104-5M-AH-PC®