MT 221: 6.

0 MATERIAL SCREENING 2019

6.0 INTRODUCTION
Screening or volumetric sizing is a method of sizing crushed or ground ore by shaking them on a suitable separating surface.
The material that passes through the apertures (screen openings) of a particular screen is known as the Undersize and the
material that remains on the screen is the Oversize, as shown in figure 1.0. Screening is generally limited to the material
above 250 µm in size; finer sizing is normally undertaken by classification. This is due to decreased efficiency in fine
screening, and that fine screens are usually expensive, fragile and tend to become easily blocked with fine particles.
Feed

Overflow

Underflow

Figure 1.0: Screening process

Screening can also be described as a consolidation of material transport rate across a screen length, stratification of undersize
particles through a bed of material and actual undersize passage through the screen holes.

6.1 Material stratification

Material stratification is a process that involves the flow of undersize particles through spaces created by oversize particles
onto a screen surface, thus, largely influenced by the concentration of fine particles in a particular feed material. Depending
on the rate of fine particles stratification, a screening process can be described as either crowded or separated. Crowded
screening usually occurs when the material feed rate is higher than the capacity of a screen surface thereby creating a thick
bed of material on the screen surface. This in turn leads to restricted undersize stratification through a bed of material due to
higher particle to particle interactions. Separated screening, on the other hand, refers to a physical separation conducted at
meagre material feed rate such that particle to particle interaction is negligible. In such a condition, undersize particles easily
stratify onto a screen surface for passage.

6.2 Material passage

Material passage is the passage of fine particles through the screen openings. While the probability of passage for a particular
particle size fraction in the feed is dependent on the amount of that size fraction on a screen surface, it has been observed
that the probability (P) of particle passage is to a large extent influenced by the relationship between particle diameter (d) and
screen aperture size (a), as shown in Equation 1.0.
d 2
P = 1 − ( ) … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … … .1
a

Hence, the higher the relative size ratio (d/a) beyond 0.8, the slower the passage rate. Considering that most screening
operations are hardly dry due to entrained moisture from the surrounding, the probability of particle passage can be extended
by incorporating the moisture content (or water quantity) (Rf) and the number of opportunities a particle contacts a screen (n)
as shown in the equation 2.0.
𝑑
P = Rf + (1 − Rf) ( ) n … … … … … … … … … . . … … … … … … … … … … … … … . . … … . . .2
𝑎
While ALL the factors mentioned are critical to particle passage, literature further emphasises that the probability of passage
of a particle is to a large extent dependent on its shape, size and angle of orientation with which it hits a screen opening, as
shown in Figure 2.0. From Figure 2.0, it can be highlighted that;
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1) Particle A is bigger than the aperture size, thence, limited passage rate regardless of the orientation on the screen
surface.
2) Particle B is smaller than the screen opening, hence, guaranteed passage in any orientation.
3) C and D represent elongated particles with one dimension bigger than the screen aperture size, and thus, the passage
is dependent on the direction with which they hit a screen aperture. In such cases, screen length plays a significant role
in giving elongated particles enough time to acquire the right of orientation for easy passage. It has also been established
that the presence of water during wet screening offers such particles higher chances of being re-oriented to a smaller
dimension for easy passage.

A B C D

Figure 2.0: Behaviour of different particle sizes and shapes on a screen surface

6.3 FORMS OF MATERIAL SCREENING

Screening can be done either dry or wet, but never on damp material.
6.3.1 Dry screening
Dry screening refers to the separation of materials in the absence of water and is usually limited to the separation of particles
larger than 6 mm. Aggregate industries have for many years struggled with improving fine dry screening, and the problem
has been compounded by the fact that many dry screening applications are rarely dry, with typical processes having a
minimum of about 3 % moisture. There are many sources of moisture in materials, but the ones that seem to cause most
problems in dry screening circuits include; weather (rain and melting snow), natural moisture in the pit or quarried material
and water added to the material for dust suppression purposes. Increased regulations on fugitive dust have in a way made it
indispensable for most producers to have water sprays installed in dry screening and crushing areas for dust suppression.
Increase in the amount of moisture in feed material beyond 3 % has an adverse effect on the performance of a screen surface
as particles tend to coagulate, thus, reducing the passage rate of undersize particles. On the other hand, during dry screening,
electrostatic charges are at times created between the screen surface and feed particles. This in a way affects the efficient
separation of particles as electrostatic charges promote particle bridging over the screen apertures.

6.3.2 Wet screening

Wet screening is typically material separation in the presence of a liquid either on coarse or fine particles. During this process,
fine particles are conveyed through the screen holes by the fluid. Hence, the quantity of the fluid in the feed play a decisive
role in the separation of particles. However, as the amount of solid particles increases, there is a corresponding decrease in
screening rate of undersize particles.

6.4 Purpose of screening

In our time, it is apparent that everything we use, wear, and eat have had in a way been in contact with or dependent upon
screens at some stage in their processing, growth and development. Screening is a process that can be applied in industries
extending from typical metallurgical and mineral processing industries to the constantly rising rationalised food, clothing, and
pharmaceutical industries. There are distinct reasons for carrying out physical separation through a screen surface, and these
may include;

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i. Grading; to generate distinct size fractions of particles using one or more screen decks in decreasing aperture sizes. It
is mostly applicable in iron ore and quarry industries were final product size specification is paramount. This process is
also used in the grading of abrasives into different grit sizes for use on various grades of sandpaper.

ii. Sizing; Separation of particles of a particular feed into different fractions by size. Material sizing by use of screens is
usually done to about 75 µm though further than this is now feasible with the evolution of vibrating screens. However,
sizing beyond 45 µm at times can be challenging and expensive; hence classification comes in handy as an alternative
method to fine material separation. There is howbeit a thin line between material sizing using a screen and classification,
and in most cases, the selectivity factor between the two processes rides on the particle size of the feed; as particles
finer than 45 µm require a large separating area.

iii. De-sliming; Separation of very fine particles from the ore material. This prevents the entry of undersize particles into
crushing machines, thereby increasing their capacity and efficiency. During desliming, about 10 % or less of the total
volume of material smaller than the mean particle size is removed i.e. removal of dust from laundry detergents.

iv. Trash removal; Removal of unwanted particles from ore material i.e. wood particles, tramp metals etc.

v. Medium recovery; Medium recovery is a process in which heavy media particles i.e. magnetite and ferrosilicon are
separated from cyclone products on a drain and rinse vibrating screen for re-use. Medium recovery is mostly applicable
in coal, diamond and iron ore industries where heavy media is used as a medium of separation.

vi. Scalping; Removal of coarse particles from the feed material usually using grizzly screens prior to primary crushing.
This ensures that coarse products do not proceed to the next stage in a closed circuit. This process is mostly used to
separate about 5 % or less of the total volume of material being screened.

vii. Dewatering; this is a process usually applied in the removal of excess water enthralled with the particles, thus improving
the pulp densities of materials going to the downstream processes. Dewatering screens essentially drain the contained
water while passing particles over a screen surface. The selection of these screens is mainly dependent on handling a
bed depth reasonable to allow free-draining of water. From literature, it has been recommended that the bed depth
chosen should not exceed three times the size of the largest particle in the feed material. Howbeit, the smaller the
average particle size of the feed material, the more difficult it becomes to drain as fine particles tend to coagulate and
hold back the flow of water through the apertures. This can be attributed to the surface tension created between the
fine particulate matter and water molecules. In such cases, the bed depth must be thin enough to allow the fluid to drain
through easily.

6.5 Types of Screens

There are two types of screens, namely; vibrating and non-vibrating screens. Vibrating screens sub-types includes resonance,
inclined, dewatering, grizzly, banana, Mogensen, horizontal, modular, and high-frequency screens. These screen types can
separate both fine and coarse particles. Vibrating screens are rectangular in shape with the feed and discharge points at
opposite ends. The non-vibrating type is a trommel screen, also known as rotary screen and is an essential unit which is used
mainly in the mineral and solid-waste processing industries.

6.5.1 Grizzlies
The grizzly is used for screening run-of-mine (ROM) ore before it goes into the primary crusher. Oversized material will go
into the primary crusher and undersize material will go to a secondary crusher or mill. Grizzlies consist of robust parallel bars

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or chains. The spacing between bars or chains is equal to the product size of the primary crusher (300 mm – 20 mm opening).
It is inclined at 20 – 50 degrees and it has a capacity of up to 5000 tph.

6.5.2 Inclined screens

These are screens used for sizing materials. Inclined screens are designed to work with either a circular or elliptical motion
that is mechanically induced onto the screen surface by the rotation of unbalanced weights or flywheels connected to a single
drive shaft. The vibration motion used depends on the angle of inclination of the screen surface. However, for screens with a
single-shaft, the screen surface is installed on a slope usually between 15 - 28 º for easy flow of material along the screen
length.

The vibration intensity i.e. frequency and amplitude of the screen influences the screening process of undersize particles. The
vibration intensity is produced by either electrical solenoids or motors usually mounted above the screen surface. Studies
have shown that increasing vibration frequency of a screen leads to a reduction in screening efficiency of near-size particles
due to the extended particle trajectory. However, increasing vibration frequency and lowering screen amplitude favours the
separation rate of fine particles due to increased contact times with the screen surface.

6.5.3 Horizontal screens

This is a class of vibrating screens with a horizontal or near-horizontal screen surface of less than or equal to 5 º angle of
inclination. Horizontal screens are mostly used in sizing operations where screening efficiency of materials is very critical i.e.
drain and rinse screens. These screens are designed to work with either elliptical or linear motion produced by either double
or triple shaft vibrators respectively. Horizontal screens have a higher particle sizing accuracy than inclined screens due to
increased material residence time on the screen surface. However, horizontal screens have comparatively low capacity due
to reduced velocity of particles along the screen length.

6.5.4 Trommel Screen

A trommel screen, also known as rotary screen, is an essential unit which is used mainly in the mineral and solid-waste
processing industries It consists of a perforated cylindrical drum which is normally elevated at an angle at the feed end.
Physical size separation is achieved as the feed material spirals down the rotating drum, where the undersized material
smaller than the screen apertures passes through the screen, while the oversized material exits at the other end of the drum.
The screen will segregate very fine materials which are not in the suitable range of size to be used in the crushing stage e.g.
coal is softer and breaks much faster than shale, coal passes through apertures as undersize meanwhile shale which is
tougher is discharged

Figure 3.0: Trommel Screen

Trommel screens are cheaper to produce than vibrating screens. They are vibration free which causes less noise than
vibrating screens. Trommel screens are more mechanically robust than vibrating screens allowing it to last longer under
mechanical stress. However, more material can be screened at once for a vibrating screen compared to a trommel screen.
This is because only one part of the screen area of the trommel screen is utilised during the screening process whilst the
entire screen is used for a vibrating screen. Trommel screens are also more susceptible to pegging and blinding, especially
when different sized screen apertures are in series. Pegging is when material larger than the aperture may become stuck or
wedged into the apertures and then may be forced through which is undesirable. Blinding is when wet material clump up and
stick to the surface of the screen.

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6.6 Types of Screen Motions

For effective material separation, vibration motion is usually induced onto the screen surface by either electrical solenoids or
motors to support the passage rate of fine particles and removal of oversize particles off the screening area. Normally, the
motors are mounted on top of the screen surface to minimize on vibratory energy losses during normal operations. The three
most important motions include circular, elliptical and linear motions; and the motion selected is largely dependent on the
angle of inclination of a separating surface.

6.6.1 Circular motion

Circular motion is a type of the movement induced on an inclined screen surface by means of an out of balance counter-
weight spinning through the centre of gravity of the screen, as shown in figure 4.0. Circular motion is usually applied to screen
surfaces with an angle of inclination not less than 15 º for ease movement of particles along a screen length. This type of
motion is mostly applicable in sizing applications as it allows particles to roll out of the openings and in turn, preventing the
screen apertures from being pegged with near-size or non-spherical shaped particles.

Figure 4.0: Circular Motion

6.6.2 Linear motion
Linear motion is stimulated by the action of similarly unbalanced counter-weights on separate shafts rotating in opposite
directions, thereby, producing a straight-line throw which passes through the centre of gravity of the screen surface, as shown
in figure 5.0. Linear motion is used on horizontal and or near horizontal screen surfaces with a low angle of inclination less
than 10 º. Coupled with high G-forces, this type of motion has a significant tendency of dislodging and transferring material
across the screen surface. From literature, it has been established that linear motion is by far better than circular and elliptical
motions as it produces high screening efficiencies with reduced aperture pegging. Furthermore, linear motion screens demand
less headroom compared to elliptical and or circular motion screens; hence, reduced installation costs. Figure below depicts
particles on the screen surface under the influence of linear motion.

O
90

O
Particle moving in a 0
Straight line motion
180O

F O
O
U 270

Figure 5.0: Linear motion

6.6.3 Elliptical or oval motion
Elliptical motion is triggered by three out of balance counterweights spinning off the centre of gravity of the screen surface.
Elliptical motion offers a combination of linear motion’s improved material separation and the tumbling effects produced by
circular motion and is mostly applicable on banana and horizontal screens. Figure 6.0 illustrates vicissitudes in motions as
particles move down a screen length under the influence of elliptical motion. At the feed end, a forward circular motion is
created by two shafts rotating in the same direction which facilitates the faster movement of oversize particles off the feed
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zone; thus, promoting the passage of fine particles. This, in turn, leads to the formation of a narrow bed of material at the
centre of the screen. Towards the discharge end, retarding effects of linear motion are produced by a third shaft rotating in
the opposite direction and thence, giving the remaining undersize and near-size particles more time to pass through the
screen apertures.
O
90

O
0
180O

F O
O
U 270

Figure 6.0: Elliptical motion

6.7 Types of screen panels
A screen panel is a surface with holes that allows undersize particles to pass through while retaining oversize particles. In
any physical separation, the screen panel selected to serve a specific material separation largely influences the performance
of a screen interms of its efficiency, capacity and the cost of running a separation process. When selecting a panel for a
specific operation, open area and screen life expectancy are the two important factors considered. Screen open area is the
percentage of the apertures against the whole separating surface and ranges from 5 – 90 %. While there is a demand for
panels with high open area and wear life, howbeit, there is an indirect relationship between the two parameters. Therefore,
there is always a trade-off between the two parameters in the designing of screen aperture configurations. Wedge wire, for
example, offers maximum open area for screening but at the expense of wear life, and the opposite is true for rubber and
polyurethane panels. Most common ones include the wedge wire, polymeric (polyurethane and rubber), hybrid panels and
perforated plates.

1. Woven wire - High “open area” and good screen efficiency. High wear rate with abrasive materials
2. Wedge wire - Comprise of wedge. wedge-shaped parallel members with small separations. Typically used for
dewatering or fine separations
3. Punched plate - Stronger than woven wire giving longer life. Different aperture shapes possible
4. Rubber - Moulded with reinforcing (steel wire cables etc.). Good wear resistance. Low open area etc.
5. Polyurethane - Good resistance to sliding wear- important in fine screening and dewatering operations. Modular
screen panels are typically used. Easy maintenance. Low open area.

6.8 Aperture shapes

There are a number of aperture shapes being used in mineral separation industry today and among them includes the square,
rectangular, circular or round, tear drop etc.

o Square apertures are most commonly used are offering accurate sizing, good wear life with reasonable open area
o Round apertures provide a strong deck surface, provide useful in heavy duty applications. Open area is lower deck
is more prone to pegging.
o Rectangular decks increase the open area and can reduce pegging. Apertures with flow are suited to screening
regular shaped particles, but not flaky material. Apertures across flow are used where pegging is likely to occur.

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Figure 7.0 aperture shapes

6.9 Factors Affecting Screening Efficiency

Many factors influence the screening efficiency of fine particles and can be grouped into design or machine factors and
operational factors. Operational factors include particle size distribution and shape, slurry density and viscosity, particle
density, feed rate, Kinetic energy of particle approaching screen opening, material flowability and friability. Design or machine
factors include screen aperture shape and size, angle of inclination, open area, screen length and width, vibration intensity
(frequency and amplitude) and quality of the screen media. Howbeit, all these factors are adjusted during material recovery
to minimise the effects of; Screen blinding - occurs when undersize particles coagulate on a screen surface and block the
apertures. Aperture plugging - occurs when critical size particles get lodged in the apertures. Material carryover - occurs when
fine particles are carried over to the oversize stream.

6.9.1 Efficiency of Screening

The most logical method, which is also the most widely used method, is based upon the recovery of undersize. An efficiency
equation can be calculated from a mass balance across a screen as shown;
F tonnes/hr
(Feed)

O tonnes/hr
(Overflow)
U tonnes/hr
(Underflow)

Figure 8.0: Mass Balance on a screen

The efficiency is expressed as the weight of the undersize actually obtained, as a percentage of the weight of the true
undersize actually in the feed:

u f  o
x100% ……………………………………………………………………..3.0
Uu
E x100% 
Ff f u  o 
Where: f = % true undersize in feed, u = % true undersize in the undersize and o = % true undersize in oversize

If we may assume that all the material in the undersize fraction is true undersize material, then u = 100 % and the equation
reduce to:
100 f  o 
x100% ……………………………………………………………….4.0
Uu
E x100% 
Ff f 100  o 
To determine the screening efficiency with this method, representative samples are taken of feed to the screen and of the
oversize and undersize fractions, and screen analyses are made to determine the percentage of undersize in feed and
products.

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ASSIGNMENT DUE ON 07.04.2020

Kindly pick a case study of any mineral processing plant that utilizes screens in their physical separation process and describe
their operation by including critical parameters. The report should include the description of the entire screening process with
inclusion of parameters measured and response variables that are used to measure or determine the effectiveness of material
separation on a screen. This should be done in consultation with the class members and will be championed by the following;

1) Metallurgy 2nd Year Class doing MT 221 – Christine Lwambula and Brighton Mwiche
2) Mining 3rd year class doing MT 321 – Obby Njanje and Ngawa Mwanza
3) Geology 2nd year Class doing MT 221 and GM 210 – Rabecca Ichidi and Trywell Siadunka
4) Metallurgy 3rd Year Class students doing MT 221 – Musonda Chimya and Melvin Simukoko
5) Mining 4th year Class students doing MT 321 – Musonda Kangwa Mulenga and Brian Mushota

The reports should be submitted by 07.04.2020 via leonardkabondo@gmail.com or leonard.kabondo@cbu.ac.zm

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