Powder Technology 347 (2019) 136–147

Contents lists available at ScienceDirect

Powder Technology

journal homepage: www.elsevier.com/locate/powtec

Review

A review on the advanced design techniques and methods of vibrating

screen for coal preparation
Liping Peng a,b, Haishen Jiang b,⁎, Xihui Chen a, Deyang Liu a, Huihui Feng a, Lei Zhang a,
Yuemin Zhao b,⁎, Chusheng Liu b
a
College of Mechanical and Electrical Engineering, Hohai University, Changzhou 213001, China
b
School of Chemical Engineering and Technology, China University of Mining and Technology, Xuzhou 221116, China

a r t i c l e i n f o a b s t r a c t

Article history: Large vibrating screen is the key equipment to improve the clean and efficient utilization of coal. In recent years,
Received 19 December 2018 various advanced design techniques and methods have been energetically explored and applied into developing
Received in revised form 21 February 2019 high-performance and long-life vibrating screen. In this paper, firstly, a systematic search of literature published
Accepted 22 February 2019
during the last fifteen years was carried out and based on the analysis on these papers, these advanced design
Available online 26 February 2019
techniques and methods were summed up as three issues: the kinetic properties of the screen body by dynamic
Keywords:
modeling, the optimal screening operational parameters by discrete element method and the dynamic design of
Coal preparation the screen body by finite element method. In detail, the traditional dynamic models of vibrating screen were clas-
Vibrating screen sified into four types according to the number of degree of freedom. Besides, four kinds of influence factors
Discrete element method pertaining to the optimal operation parameters of a vibrating screen were presented. Moreover, two aspects of
Advanced design techniques dynamic design process, i.e., the dynamic analysis and the optimal design strategy of the screen body was intro-
Dynamics modeling duced. Finally, based on the comprehensive review, some topics such as a concordant optimal method on screen-
ing operational parameters, the appropriate control method for stable operation of a large vibrating screen, and
the precise kinetic properties of screen body by dynamic modeling were recommended.
© 2019 Elsevier B.V. All rights reserved.

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2. Research method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3. Kinetic properties of screen body by dynamic modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
4. Screening operational parameters by DEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.1. Test-based DEM simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.2. Industrial application-oriented DEM simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5. Dynamic design of the screen body by FEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
5.1. Dynamic analysis of the screen body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
5.2. Optimal design of screen body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6. Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7. Recommended areas of research . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

1. Introduction

For the clean and efficient utilization of coal, coal preparation is an

⁎ Corresponding authors. important measure to solve the problem of air pollutant emissions,
E-mail addresses: haishen_jiang2015@163.com (H. Jiang), ymzhao_paper@126.com
solid waste generation and save coal resources in the world [1,2].
(Y. Zhao).

https://doi.org/10.1016/j.powtec.2019.02.047
0032-5910/© 2019 Elsevier B.V. All rights reserved.
 L. Peng et al. / Powder Technology 347 (2019) 136–147 137

Screening is the basic process for cleaning and efficient utilization of

coal, and is mainly realized via vibrating screen [3]. A conventional
large-scale coal preparation process in China is shown in Fig. 1 [4].
After the raw coals are treated by the separator, vibrating screen,
crusher, centrifuge, the particle size decreases from more than
100 mm to the final 2–25 mm, and meanwhile, the ash content de-
creases from 27.8% of the raw coal to 8.1% of the final clean coal. During
this coal preparation process, the vibrating screens used include a flip-
flow screen for classification, a desliming screen for reducing slime con-
tent, a sieve-bend screen for dewatering, and a medium-draining screen
for dewatering or removing the medium [5,6]. According to some statis-
tics, the vibrating screen accounts for 25%–33% of the total equipment in
a modern coal preparation plant [7,8] .
The main structures of a vibrating screen are as shown in Fig. 2 (a). It
usually consists of a screen body, a screen surface, four groups of vibra-
tion isolation system, and an excitation system (i.e., a unilateral-driven
system and two box-type exciters). The screen body is a composite
structure composed of two side panels, an excitation beam, several
bearing beams and stiffeners and so forth. The screening process is illus-
trated in Fig. 2(b). Under the strong alternating load generated by rota-
tion of the box-type vibration exciters, the screen surface is engaged in a
reciprocating motion with an acceleration of nearly 50 m/s2, thus
promotes the feeding coal with a larger size than the screen hole's di-
mension to convey on the screen surface to be oversized product at
the discharge end, and the rest move through the screen surface to be
undersized product [9].
In reality, a large vibrating screen, which has a screen surface width
of no less than 3.6 m and a screening area of no less than 20.0m2, usually
Fig. 2. Schematic diagram of (a) a vibrating screen and (b) screening process.
oscillates with extremely complex dynamic characteristics of the screen
body [10,11]. As shown in Fig. 2 (b), generally, except for the dominated
strong alternating load yielded by two box-type exciters, a large vibrat- load induced by the collision of screening coals, i.e., the feeding with
ing screen may also withstand the inertial load of the screen body fluctuant rate and the jumping on the screen surface [12,13]. Under
(i.e., probably five times of the gravity of screen body) and the impact the sustaining coupling effect of such three kinds of loads, structural

Coal size Raw coal Ash capacity

Ash=27.80%
LARGE Classificaon HIGH
Vibrang screen
<100 >100

Classificaon Crusher
Flip-flow screen
<6 >6

Mixed coal Desliming screen Desliming

Ash=21.40% >6 <6

Shallow groove
dense medium separator Sieve-bend screen Dewatering
Mediumdraining Mediumdraining
& Desliming & Desliming Staonary screen
Gangue Fine coal
mediumdraining screen centrifuge
Clean coal Qualified
mediumdraining screen medium
Gangue Dilute Qualified >25 25-2 slurry system Mixed coal
Ash=80.10% medium medium Ash=22.30%
Dilute Qualified
Crusher medium medium
Clean coal
centrifuge

SMALL Clean coal Dilute medium bucket LOW

Ash=8.10%

Fig. 1. Application of different kinds of vibrating screens in coal cleaning production (without sub-system of slime water treatment).
138 L. Peng et al. / Powder Technology 347 (2019) 136–147
damage such as the fracture of auxiliary beam, exciting beam and bear-
ing beam as well as the crack of side panel or vibration isolation system
often occurs, which results in the dissatisfactory of large-scale coal
cleaning production demand [14]. With the construction of 10-
million-ton-level large coal preparation plants for a large-scale clean
coal production, there is an increasingly widespread demand for large
vibrating screen with high screening performance and mechanical reli-
ability [15,16].
To ensure the screening performance and service lifetime, in the
development process of vibrating screen of the last decade, some
advanced design techniques and methods have been extensively ap-
plied [17]. In this paper, a systematic search of literature was carried
out to perform a review on developments in advanced design tech-
niques and methods of vibrating screen. A brief description of the
importance and content of advanced design techniques and methods
for vibrating screen will be presented in Section 2 and then a detailed
state-of-the-art review from three aspects will be given in Sections
3–5. Finally, Section 6 will conclude this study.
2. Research method
The literature taken for survey were published during the last fifteen
years (2004–2018). As illustrated in Fig. 3(a), the attention was partic-
ularly focused on the published work of last five years, which is almost
71% of all the literature. Main of the literature are journal papers and sci-
entific conference proceeding papers. The databases Web of Science,
Scopus, Springer, Taylor Francis and Google Scholar were used for the
English literature search and the CNKI was used for the very few Chinese
literature search. The keyword search included the strings “vibrating
screen”. All these papers were read carefully and thoroughly before
we conducted the review.
Fig. 3. Distribution of the publications according to the published year (a) as well as the three aspects for designing a vibrating screen (b) and overview of the technology system (c).
We have found that there is a consensus among the researchers that
a vibrating screen with high screening performance and mechanical
reliability is urgently needed. By reading these literature, it can be
found that the improvement of screening performance and mechanical
reliability relies on (i) the kinetic properties of the screen body, (ii) the
optimal screening operational parameters and (iii) the dynamic design
of the screen body, as summarized and illustrated in Fig. 3(b). The three
issues almost draw the same attention of researchers. However, there
isn't a detailed study covering all the three aspects. In this regards, a
comprehensive review of advanced design techniques and methods
for a vibrating screen, and the recommended areas of research have
been presented in this study.
The advanced design techniques and methods of a vibrating screen
is illustrated in Fig. 3(c). In order to achieve an efficient coal-screening
process, it is necessary to ensure that the kinetic properties of the screen
surface or the screen body, such as the trajectory, the amplitude and the
frequency, satisfy the law of coal permeability characteristic [18]. These
kinetic properties of a vibrating screen under a certain working load can
be determined by dynamic modeling, so the screening system dynamics
is the basis for designing a vibrating screen [19,20]. In actual application,
after the design and manufacture of a vibrating screen, the correspond-
ing screening operational parameters need to be well adjusted by many
physical screening tests for different feeding coals to achieve the best
screening performance, namely, the screening efficiency and the
screening capacity. However, such adjustment process might be cost-,
labor- and material-consuming and affects production. In order to accel-
erate the adjustment, the virtual screening test by numerical simulation
based on the discrete element method (DEM), to a large extent, can be
carried out to replace the physical screening test, and predict the opti-
mal screening operational parameters [21,22]. After the kinetic proper-
ties of screen body and screening operational parameters determined, a
physical prototype may be magnified to be an ultimate product, namely,
 L. Peng et al. / Powder Technology 347 (2019) 136–147 139

a large vibrating screen. However, before it is widely-manufactured,
dynamic analysis and optimum design by finite element method
(FEM) should be carried out to analyze the dynamic characteristics
and then guarantee the reliability [21,23]. It should be noted that opti-
mum design procedure only improves mechanical performance of this
equipment rather than the screening effect. That is to say, the DEM-
based optimal screening operational parameters analysis is to make
the actual vibrating screen operate in a better condition while the
FEM-based dynamic design of screen body is mainly to strengthen the
service lifetime before manufacturing.
3. Kinetic properties of screen body by dynamic modeling
On the precondition of the same dimension of the screen body, a
larger screening efficiency can accomplish a large screening capacity.
For an efficient coal-screening process, the kinetic properties of screen
body should accord with the law of coal-screening principle. As we
know, the blinding of apertures with near-mesh coal particles is inevita-
ble in practice and can affect the other particles passing through the
screen surface. For the traditional large vibrating screen, the method
to reduce the blinding is to improve the vibration intensity of screen
body. The vibration intensity (k = Aω2/cosα/9.8) depends on the vibra-
tion direction angle (α), amplitude (A) and frequency (ω) of the screen
body [24]. During the whole screening process, a large amplitude at the
feeding end can enhance the particle-swarm motion and reduce the ac-
cumulation, while a small amplitude at the discharge end can increase
the probability of particle-swarm touching the screening surface and
promote the particle penetration.
The motion of screen body in a steady state can be decomposed into
several displacement components and each displacement component
can be expressed by the Cartesian coordinate and called as the degree
of freedom (DOF) [25]. The kinetic characteristics of screen body are
usually obtained from solving the dynamic equation established based
on the dynamic model, which is often created according to vibration
theory [26,27]. As summarized in Table 1, traditional dynamic models
of vibrating screen can be classified as the low-DOF models on a two-
dimensional (2D) plane, including 1-DOF (1-translational), uncoupled
2-DOF (2-translational), coupled 3-DOF (2-translational +1-rotational)
dynamic model and the spatial 3-DOF model. Table 1 also presents the
principle for establishing dynamic equation of each dynamic model
and the principle is that the resultant force or moment in each DOF
should be zero.
As a kind of vibration machine, the dynamic model of a vibrating
screen is similar to the other vibration machine, such as a vibration
feeder [38,39], and they are all belong to a mass-damping-stiffness sys-
tem in the vibration theory. From the view of engineering applicability,

Table 1
Traditional dynamic models for motion description of vibrating screens.

Dynamic model and the dynamic model description Principle for Application of the dynamic model
dynamic
equation
P* ➢ Develop a new resonance vibrating screen [28];
Fz ¼ 0
➢ Study the influence of screening coals on a vibrating screen [11].

8 *
<P F ¼ 0 ➢ Study vibration characteristics of a banana flip-flow vibrating screen [19];
x
➢ Develop a vibrating screen with an added mechanism suspension for low noise [29];
:P*
Fy ¼ 0 ➢ Develop a novel low-noise vibrating screen [30].

8P*
>
> Fx ¼ 0 ➢ Study maximal amplitude of the screen body [31];
>
<
P* ➢ Study the influence of feed materials on vibrating screen [32];
> F y ¼0 ➢ Develop control algorithm for a vibrating feeder with four eccentric rotors [33];
>
>P *
: ➢ Study synchronization transmission in vibrating machine [34];
Mθ ¼ 0
➢ Study a more accurate dynamic model for vibrating screen [3].

8P*
>
> Fx ¼ 0 ➢ Conduct a qualitative fault diagnosis of the damping springs of a vibrating screen [35,36];
>
<
P* ➢ Conduct a quantitative fault diagnosis of the damping springs of a vibrating screen [37].
> Mθ ¼ 0
>P *
>
:
Mφ ¼ 0
140 L. Peng et al. / Powder Technology 347 (2019) 136–147
the 1-DOF and 2-DOF models are the simplest and most commonly im-
plemented in the actual vibrating screen design [40]. Such two models
are suitable for vibrating screen with line-trajectory, namely, the screen
body undergoes simple harmonic motion and the law of motion of each
position in the screen is the same. However, with the rotation of screen
body and its influence on the transverse and longitudinal motion
of screen body considered, a panel 2-DOF model will develop into a 3-
DOF one [41]. The screen body would undergo simple harmonic motion
and the law of motion of each position in the screen is different. For
example, Baragetti and Villa proposed a panel 3-DOF coupled (2-trans-
lational +1-rotational) for heavy loaded vibrating screen, and utilized
finite element software for structural revision [23], and verified the ki-
netic analysis results via stress and strain tests [42]. Most of the 3-DOF
are established based on the traditional damping spring system, which
consists of four metal helical springs. In particular, a general dynamic
model for a vibrating screen with hybrid-spring isolation system was
developed and the mathematical description equations was derived,
and the sensitivity of the longitudinal natural frequency to the mount-
ing position as well as the stiffness values of suspension springs was in-
vestigated. Both the experimental test and the theoretical analysis
shown that the suspension springs can make the screen body oscillate
in a more stable condition [43]. Besides, for some off-design operation
conditions, several panel 3-DOF dynamic models with nonlinear charac-
teristics have been studied for investigating the vibrating screen motion
with a failure of isolation system [26], or during the startup and shut-
down period [33,34].
The studies mentioned above have mainly focused on the dynamic
models for traditional low-DOF vibrating screens with plane motions.
In contrast, a spatial 3-DOF model, which was proved to have a down-
ward compatibility and could represent the plane 1- and 2-DOF models,
was found [36]. However, it should be pointed out that the spatial 3-
DOF model was mainly used for fault diagnosis of the vibration isolation
system [35]. For the limitation of the acceleration of the screen body,
these vibrating screens are easy to suffer from the blinding of screen
surface when sieving the moist coal. In order to solve the problem, the
acceleration of the vibrating screen should be enhanced to improve
the ability of particles penetration [44]. Therefore, a 17-DOF dynamic
model for a vibrating screen with an elastic screen surface was
established, whose screen body motion was presented only by the
first DOF and the rest 16 DOFs were used for the elastic screen surface
[45]. It was proved that the vibrating screen with an elastic screen sur-
face has a larger vibration acceleration than the traditional vibrating
screen. Another kind of vibrating screen for processing moist coal is
the high-frequency vibrating screen with parametrically excited screen
surface, whose dynamic model is a multiple-DOF plate model [46] or a
string structure model [47] and the excitation frequency would have a
significant effect on the vibration amplitude of the screen surface.
All in all, kinetic studies on vibrating screen by dynamic modeling
have made significant progress, however, they are still confined by the
dynamic problems of screen body and static screen-particle-swarm sys-
tems, in which the screen-particle-swarm system is basically regarded
as a static inertia block and only improves the mass of screen body.
Actually, the motion of the screening coals may affect the kinetics prop-
erties of screen body.
4. Screening operational parameters by DEM
With the traditional dynamic model for kinetic analysis process of a
vibrating screen established, the external input excitation parameters
(i.e., the excitation frequency and amplitude) screen and its physical
properties (i.e., the screen size, the vibration mass and the vibration iso-
lation system parameters) can be input into the dynamic model, then
the screen body movement characteristics can be identified. In practice,
when these motion characteristic parameters need to be adjusted, only
the excitation parameters can be changed, and the adjustment principle
is determined by the vibration intensity of screen body required by DEM
to simulate the optimal screening effect. Therefore, to a certain extent,
DEM simulation provide a guidance for the kinematic characteristics de-
mand. Hence, the screening theories or screening mechanisms for coal
preparation lay the foundation of developing and fabricating vibrating
screen, and virtual screening tests by DEM analysis can provide an effi-
cient way of investigating screening theories and mechanisms. At pres-
ent, the DEM is mainly employed to build phenomenological screening
process models for vibrating screens, and based on DEM, dynamic sim-
ulations are performed on the screen-particle-warm of the screening
process with the purpose of exploring the kinetic characteristics of the
particle swarm or probing into the screening mechanism, evaluating
the effect of screening, and finally optimizing operational parameters
[48,49]. The procedure should be repeated by adjusting the influence
factors (IF) until the optimal operation parameters are determined, as
shown in Fig. 4.
Up to now, the studied IF can be classified into (i) the feeding parti-
cle parameters (i.e., the feed particle size distribution [50,51], feed rate
[48,52], particle shape [53] and inter-particle cohesion of the moist
coal [54]), (ii) the screen body vibration parameters (i.e., the screen in-
clination [44,48], vibration direction angle, amplitude and frequency
[24,49,51,55-59]), (iii) the screen deck parameters (i.e., the aperture
size [48], shape and number of screen deck [60,61]) and (iv) the simu-
lation parameters (i.e., the particle creation method [48,55] and the sim-
ulation time [51]) in DEM. With the influence factors determined, the
optimization goal can be the overall screening efficiency, the screening
capacity, or the partition coefficient, etc. [48,55,56]. As the DEM can out-
put some statistical data of the coal particle motion, mass or load, these
optimization goals can be quantized by some formulas with the corre-
sponding data generated by the DEM simulation. For example, the over-
all efficiency of screening process was calculated by (c-f)/c/(1-f), where f
is the fraction of oversized particles in the feeding coals and c is the frac-
tion of coals above the cut size in the oversize stream [48]. Liu et al. has
summarized the application of 2D DEM in the vibrating screening field
[62]. In this section, we will mainly discuss the DEM simulation tech-
nique with three-dimensional (3D) discrete element models from the
two aspects of the test-based DEM simulation and the industrial
application-oriented DEM simulation. Such two aspects are distin-
guished by the DEM model size and the simulation computing cost.
4.1. Test-based DEM simulation
Test-based DEM simulation is a virtual screening test for small-sized
screening models and needs little amount of computation, whose re-
sults can be applied into the practical production of a vibrating screen
efficiently. For example, Elskamp and Kruggel-Emden performed a con-
tinuous steady-state virtual screening test on a screen surface with a
scale of 100 mm × 350 mm, and obtained a steady-state spatial identi-
fication screening model and a steady-state separating curve model
[49]. As mentioned in Section 2, a vibrating screen may also withstand
the impact load induced by the collision of screening coals, but up to
now, no effective means to directly test such impact load have been
found, therefore, based on Fannie's wear theory, DEM was also adopted
to establish the rules for calculating the erosive wear effect of particle
swarm for a 100 mm × 300 mm screen surface [63]. It has been founded
that main of the test-based DEM simulation studies focus on the prob-
lems of screening dry particles. Actually, the DEM simulation can also
be used to analyze the flow velocity field, spatial distribution, and the
retention characteristics of wet particles on a narrow static bent screen
surface, and then to predict the screening effect of a small-scale screen
surface, and discuss the influence of the screen plate opening on mate-
rial flow velocity and the screening effect [64].
Given that the vibrating screen model adopted by test-based DEM
simulation is relatively small and to some extent, the particle swarm
count and characteristics may differ from the reality once the model is
scaled up, the accuracy of simulation results still needs to be verified be-
fore the practical applications. Verification of DEM simulation is mainly
 L. Peng et al. / Powder Technology 347 (2019) 136–147 141

Adjust Explore kinec Evaluate

DEM Conduct IF parameters characteriscs of screening
analysis DEM modeling
procedure: (i) (ii) (iii) (iv) parcle swarm performance

IF = feed parcle size IF = screen inclinaon

distribuon [50,51] feeding parcle [44;48]
parameters
IF = feed flow rate
[48,52] (i) IF = amplitude(A),
IF = parcle shape (ii) screen body vibraon
direcon angle(α),
[53] parameters
frequency(ω),
IF = Inter-parcle [24,49,51,55-59]
cohesion [54]
(iii)
IF = aperture size
[48] IF = parcle
(iv) creaon method
IF = aperture shape simulaon parameters [48, 55]
[60] screen deck
IF = number of parameters IF = simulaon
screen deck [60] me [51]

Fig. 4. Overview of the DEM analysis and the studied IF parameters during the DEM simulation for a vibrating screen (the picture is reproduced from [54]).

performed via the screening test on a physical prototype for laboratory
screening [65,66]. Such laboratory-scale prototype should be designed
according to the similarity theory, which means that the prototype
and the industrial vibrating screen should meet the geometry similarity,
stress-strain similarity, and the initial conditions and boundary condi-
tions similarity, et al. [67]. Up to know, there are only few reports on
verifying DEM simulation, which can be classified into the following
two kinds of methods:
One way to verify the simulation is biased towards the screening
process evaluation. Generally, a typical DEM simulation and the corre-
sponding verification test system is shown in Fig. 5(a), which mainly
includes the screening device (a small vibrating screen), light source,
high speed camera, computer and the simulation software [55,68].
High-speed camera and the corresponding simulation analysis software
are utilized to capture the photographs of the actual screening process
and analyze the coal movement characteristics, such as the velocity,
the acceleration, and the distribution of the coal materials on the screen
and so on (Fig. 5b). Then, compared with the simulation results (Fig. 5c)
under the same test conditions, the accuracy of the DEM simulation test
can be verified or if necessary, the simulation test conditions and pa-
rameters setting would be further modified. For instance, a screening
test on a variable-incidence prototype (150 mm × 900 mm) to verify
the results of 1D and 2D virtual experimental simulation was performed
by Hilden [69], and he proposed the characteristic transformation
criteria used from prototype test to industrial practice.
The other way to verify the simulation is to compare the ultimate
screening performance. Results from the DEM simulation and a screen-
ing test on an experimental vibrating screen are compared quantita-
tively with the same operating conditions. The comparison criterions
can be the screening efficiency per second [56], the partition coefficient
and the screening efficiency [48,70] and the particle flow rate [71]. For
instance, Zhao et al. conducted an experimental study on a circular-
trajectory vibrating screen prototype that was 365 mm × 710 mm in
size, and they compared the test results of screening efficiency, the mo-
tion trail of particles of different size fractions and their motion velocity
on the screen surface with the results in DEM simulation, and then they
modified the particle shape modeling method in DEM software config-
uration [68]. In practice, to investigate and analyze the rules of influence

Fig. 5. DEM simulation and verification: (a) the high-speed dynamic analysis system of the vibrating screening process, (b) snapshot of the screening processes in experiment, (c) snapshot
of the screening processes in DEM simulation [68].
142 L. Peng et al. / Powder Technology 347 (2019) 136–147
for the above factors and their interactions on the efficiency of screen-
ing, it is necessary to bring in the orthogonal experimental design
method for reducing the physical experimental cost and the DEM simu-
lation times of repetition [55]. Also, the experimental data together with
the DEM results can be used for mapping the feasible sample space of
operating parameters by regression modeling and then the ultimate op-
timization can be implemented using some intelligent algorithms, such
as the particle swarm optimization method [70].
Most of the DEM simulations of screening process begin with the hy-
pothesis that the coals are spherical particles, which can directly affect
the calculation accuracy of the contact force between the two non-
spherical particles common in practice. It has been proved that the
DEM simulation results with non-spherical particles have a smaller
error with the experimental verification results than that of spherical
particles. Besides, whether the particle size distribution of the simulated
particles matches that of the experimental ones or not, would also affect
the screening technological parameters [71]. Thus, the particle charac-
teristics during DEM simulation should be set up to be in a good agree-
ment with the experimental system firstly.
4.2. Industrial application-oriented DEM simulation
For the limitation of computational simulation cycle and cost, cur-
rently there has been little coverage of direct DEM simulation studies
on a large industrial vibrating screen, even if the direct DEM simulation
on a large industrial vibrating screen can avoid the distortion or inaccu-
racy when transforming the results in a scale model into the industrial-
application one [58]. Comparing with a scale model, an industrial
vibrating screen are easier to be affected by the dynamic impact of
large-scale screening coals, especially in off-design condition, which
may have a negative effect on determining the influence parameters
in Fig. 6 as well as the mechanical reliability. Besides, as shown in
Fig. 6a and b, with the help of DEM, the average approximate periodic
impact load of coals on the screen surface can be conveniently obtained
in the process of screening simulation. Undoubtedly, the impact will
cause the increase of the stress characteristics of beam structures, as
shown in Fig. 6c [11,24]. Therefore, the screening coals enhance the
structural stress and further improve the possibility of occurrence of
beam structural damage. This phenomenon may be more apparent in
the large-scale screening process in the industrial vibrating screen.
Results of an industrial application-oriented DEM simulation has
been directly applied into the guiding the operational parameters ad-
justment for a better screening performance. Cleary and Sinnott
[72,73] and Fernandez et al. [74] applied DEM to a double-layer
banana-shaped vibrating screen that had dimensions of 2.4 m × 6.1 m,
they adopted spherical particles in order to investigate the relationship
between the dynamic parameters of coarse and fine particle swarms
such as layering, leaking screening and screen surface acceleration,
and they also probed into the distribution of stress imposed by the
Fig. 6. Impact load on the screen surface (b) by screen coals extracted from DEM simulation (a) and the enhanced structural stress (c) by impact load.
materials on the screen plate. Later, considering the previous results in
terms of particle velocity and volume were not convenient for engineer
to use, the industrial vibrating screen above were adopted and analyzed
by LIGGGHTS software to study on the mass of under-size product
through screening simulation as well as the method to obtain the best
optimal operation parameters [51]. Additionally, as the coal particles
are easy to be moist and sticky, the effect of inter-particle cohesion
with low, intermediate and high cohesion levels on the flow and sepa-
ration of the vibrating screen above were studied by DEM, respectively
[54]. During the simulation, the cohesion level can be characterized by
the software setting of the Bond Number (BN).
In the process of industrial application-oriented DEM simulation, the
composite coupled system, namely, the screening particle swarm-
screen body system, has been adopted to quantitatively evaluate the in-
teractions between the two, thus providing a basis for the advanced
mechanical design of a vibrating screen.
5. Dynamic design of the screen body by FEM
During the traditional design process, the static design method
based on stress and strain has been widely adopted [75,76]. For the
bearing beam and auxiliary beam, with the dimension, material and
shape selected, the calculated dynamic inertia load and the static load
by the equivalent conversion of self-weight are directly and uniformly
distributed horizontally on the beam structure, and the bending
strength is checked to be in the allowable stress range [77]; for the ex-
citing beam, apart from the two loads above applied on it, it is also nec-
essary to count into the concentrated strong alternating load of the two
box-type exciters [78]; for the side panel, the crossbeam width of the
screen body alone is used to determine the thickness of the side panel
by experience. To a certain extent, this static design method has given
rise to large equipment design safety margins, however, it may waste
materials and increases the vibrating mass of a vibrating screen [79].
As has been demonstrated practically, the fatigue failure forms of the
screen body mainly include crossbeam fractures caused by alternating
bending stress, and side panel cracking incurred by the shear stress
and fatigue damage of the beam-panel conjunction plane [52]. In fact,
as a vibration utilization equipment, the structural dynamic characteris-
tics of screen body should be taken into consideration when designing a
vibrating screen. The typical dynamic design process of a large vibrating
screen is as displayed in Fig. 7 [80] and its basic idea can be summarized
as follows: Firstly, the empirical design of a vibrating screen is con-
ducted to determine the fundamental structural shapes and dimen-
sions. Secondly, a corresponding 3D model is established based on the
empirical design to verify the assembling ability. Thirdly, the dynamic
load of coal particles on the screen structure is extracted by the DEM
software [81,82], which together with the exciting load of the vibration
exciters, can be applied to the screen body and then the structural per-
formance of the screen body can be evaluated using the FEM analysis as
 L. Peng et al. / Powder Technology 347 (2019) 136–147
Fig. 7. Dynamic design process of a large vibrating screen.
well as a practical test based on a prototype. During this period, one can
identify the structural position under the most prominent local stress as
a vulnerable site. Finally, the structural dynamic stresses of all the dis-
covered vulnerable sites will be reduced or distributed uniformly by
screen structure modification such as optimizing the arrangement of
structural type, size, position or installing additional beam rib, stiffener
and so forth [83]. Such advanced design process may improve the dy-
namic characteristics and form a high-performance vibrating screen.
In the following part, the two aspects of dynamic design process,
i.e., the dynamic analysis and the optimal design strategy will be
introduced.
5.1. Dynamic analysis of the screen body
Given that a single beam has a span of at least 3.6 m for a large
vibrating screen, any elastic deformation of the beam structures will in-
duce the side panel to experience bending and torsion deformation, and
further weaken the overall stiffness and reliability of the screen body.
Up to now, studies on the dynamic design of the screen body have
mainly concentrated on the FEM analysis of the overall screen body
structure. Generally, the FEM analysis software was employed to obtain
the vibration modes, natural frequencies, and stress characteristics of a
vibrating screen under harmonically forced vibrations, and based on
which the researcher can judge the large-deformation or low-stiffness
positions of the screen body. These positions are recommended to con-
duct the structure modification [84,85]. Morever, some other methods
or technology like the computational mechanics, graphics and the ex-
perimental modal technique was adopted by Wang et al. to carry out
the dynamic simulation of a 27m2 vibrating screen, and they draw the
conclusion to improve the auxiliary beam and side panel design of the
screen body [86]. Similarity, Yin et al. used ANSYS for analysis, and con-
cluded that the structurally vulnerable sites of the vibrating screens all
occurred in the stiffeners at feeding end and the triangular area of side
panel [87]. For a precise FEM analysis, Peng and Su described the ele-
ment selection, joint area stiffening, and other techniques related to
the building of dynamic finite element models for large vibrating screen
in detail [88].
In addition, some important components of a vibrating screen can
be analyzed separately to evaluate the corresponding dynamic
143
characteristics, i.e., the strain, stress and deformation under a desig-
nated or extreme work condition [89]. The critical plane method
based on a multi-axial load fatigue analysis was used to conduct numer-
ical analysis on the fatigue life of a large vibrating screen [67]. The
stress-strength interference model was adopted to predict and calculate
the fatigue reliability of vibrating screens, and assess the degree of influ-
ence that surface processing quality had on the fatigue reliability of vi-
brating screens [90]. And during the early design of a vibrating screen,
a parametric FEM simulation of damping spring component was imple-
mented for adjust the kinetic and dynamic properties [79].
Apparently, the dynamic analysis method based on dynamic re-
sponses meets the mechanical characteristic analysis demand of vibrat-
ing screens as vibration utilization equipment. According to the
cumulative damage theory, the fatigue failure of materials is caused by
the constant action and accumulation of cyclic load, which main leads
to the mechanical structure damage, so it is necessary to further analyze
the fatigue life of screen body structure. However, this aspect is rarely
investigated for a vibrating screen.
5.2. Optimal design of screen body
The optimal design method is mainly based on certain optimization
principles or target functions, and, with regard to the optimal arrange-
ment of the additional confining materials controlling the dynamic
stress of the screen body. It aims to realize a low level or a uniform dis-
tribution of the dynamic stress on screen body and meanwhile reduce
the manufacturing cost by saving the materials.
The current research on optimal design of screen body focuses on
the beam structures and side panel. For example, the dynamic topology
optimization method is often used for panel structure stiffening under
multiple frequencies constraints, and to improve the screen body stiff-
ness of vibrating screens [91]. Expect for the multiple frequency con-
straints, the analytical sensitivity method is also a feasible method to
optimize the structural size of the side panel stiffeners of a vibrating
screen [92], and the augmented Lagrangian method can be applied
into seeking the optimal arrangement of side panel stiffeners for a
low-stress target [93]. As the similar model of a large vibrating screen
is able to predict the practical dynamic characteristics of a large vibrat-
ing screen, it can be studied instead of a larger one for a more efficient
144 L. Peng et al. / Powder Technology 347 (2019) 136–147

analysis and to proposed the optimal design tragedy, such as increas-
ing the stiffness of the crossbeam and the horizontal support stiffness
of the side panel [67]. Baragetti et al. modified the side panel and
changed the conventional clumpy side panel into a box-type structure
composed of two relatively thin side panels and their connectors, and
eventually the FEM analysis results indicated that the vibrating screens
saw improvements in fatigue resistance and stiffness after this
modification [23,42]. Peng et al. improved the theory about the beam
body dynamics design of large vibrating screens, and claimed that
beam body design should take into account the influence of stochastic
load [94].
Optimal design of a vibrating screen also contains the innovative de-
sign of screen body. A novel high-strength large vibrating screen with
duplex statically indeterminate mesh beam structure was invented

Fig. 8. Comparison of (a) a vibrating screen with duplex statically indeterminate mesh beam structure and (b) a vibrating screen with traditional structure [24].
 L. Peng et al. / Powder Technology 347 (2019) 136–147
[85,95], and the theoretical analysis, the FEM analysis and the experi-
mental validation were conducted to investigate its dynamic character-
istics and structural strength. To demonstrate that such vibrating screen
has an advantage of high reliability and long service time, a model of a
traditional vibrating screen with the same vibrating mass and dimen-
sion was established for comparisons [24,96]. As shown in Fig. 8, the tra-
ditional vibrating screen has a peak stress of 130.53 MPa and the
vibrating screen with duplex statically indeterminate mesh beam struc-
ture has a peak stress of 64.54 MPa, which is significantly less than that
of the traditional one. Except for changing the screening structure, a
kind of magnetorheological fluids damper was applied for altering the
structural damping ratio of a vibrating screen to improve the screening
efficiency as well as to decrease the vibration of the screen base frame,
which is helpful for keeping the performance [97,98]. Unlike the metal
helical spring in traditional vibrating screen, a kind of spring made by
alloy with shape memory was used for changing the natural frequency
by adjusting the environmental temperature. The experimental investi-
gation demonstrated that such spring is suitable even if vibration mass
changes by as much as ±30% [99]. Recently, a reconfigurable vibrating
screen based on the reconfigurability theory has been invented to im-
prove its capacity and productivity, which is suitable for the adjustable
required capacity [10,100].
6. Conclusions
(1) A large vibrating screen is crucial to advancing the large scale coal
preparation for the clean and efficient utilization of coal. A com-
prehensive review of advanced design techniques and methods
for a vibrating screen have been presented. Almost 71% of all
the literature were published during last five years.
(2) The screening performance and mechanical reliability of a vibrat-
ing screen depends on the kinetic properties according to the law
of coal-screening principle, the optimal screening operational
parameters and the dynamic design of large vibrating screen
structures.
(3) Around one third of all the reviewed publications discussed the
dynamic modeling for studying the kinetic properties of a vi-
brating screen. The traditional dynamic models of vibrating
screen are low-DOF models and can be classified into four
types, among which, the 1-, 2-, 3-DOF models are established
on a 2D plane for designing a vibrating screen while the spatial
3-DOF model is mainly used for fault diagnosis of a vibrating
screen.
(4) Also, there are some particular dynamic models developed for
the vibrating screen with different structure described in Fig. 2
(a), such as a vibrating screen with an elastic screen surface, a
plate model or a string structure model.
(5) The DEM analysis is a kind of virtual screening test technology to
determine the screening operational parameters. It consists of
the test-based DEM simulation and the industrial application-
oriented DEM Simulation. When conducting a DEM simulation,
the effect of the four kinds of influence factors, on the kinetic
characteristics of the particle swarm and the ultimate screening
performance are usually investigated.
(6) The test-based DEM simulation is usually verified via the screen-
ing test on a physical prototype for laboratory screening, while
the industrial application-oriented DEM simulation results can
be directly applied into the guiding the operational parameters
adjustment for a better screening performance.
(7) Dynamic design of large vibrating screen structure by FEM is an
advanced technology that is quite different from the traditional
static design method. Expect for the fundamental dynamic anal-
ysis and the optimal design of the screen body by FEM analysis,
the DEM can also be used to obtain the dynamic load of coal par-
ticles on the screen structure and applied into the analysis for a
more precise result.
145
7. Recommended areas of research
(1) As shown in Fig. 4, if a vibrating screen is model a 1-DOF dynamic
model, the amplitude A is almost inversely proportional to the
square of the frequency ω; Besides, the adjustment of A and ω
also have an effect of the value of the direction angle α. Hence
in practice, an interactional relation exists among them and it is
not really appropriate for studying the screening operational pa-
rameters by DEM only through adjusting the direction angle (α),
amplitude (A) and frequency (ω), separately. So it is better to
consider a concordant optimal method of these parameters.
(2) Efficient sieving for the large-scale coal preparation and high re-
liability for the vibrating screen requires the screen body to oper-
ate as smoothly as possible. Thus, aiming at the vibrating screen
with a width of more than 3.6 m, the amplitude difference of
the two sides of the screen body should be less than 0.5 mm,
and the lateral swinging should be less than 1.0 mm. As the
screen width increases, the rigid-flexible coupling characteristics
of the large-span transmission apparatus of the excitation system
may lead to inaccurate synchronization of the two groups of box-
type exciters. Meanwhile, the one-way offset of the motor may
generate an unbalance torsional torque to make the screen
body sway. Such two factors have a negative effect on the smooth
operation of the screen body and need to be suppressed.
(3) The complex dynamic excitation of coal particle swarm also has a
profound influence on the stable operation of a vibrating screen.
Therefore, it is necessary to propose an appropriate control
method based on the dynamic research of coupling system of
particle swarm and screen body. Besides, it should be noted
that the random fluctuation of additional vibrating mass caused
by particle swarm makes the screening system change from
time-invariant system to time-varying system. Thus, the precise
kinetic properties of screen body by dynamic modeling might
be hard to obtain.
Acknowledgements
This work is supported by the National Natural Science Foundation
of China (Grant NO. 51605138, NO. 51775544), the Fundamental Re-
search Funds for the Central Universities (Grant NO. 2018B22614), the
Natural Science Foundation of Jiangsu Province (Grant NO.
BK20160286), the Postgraduate Research Innovation Program of
Hohai University (Grant NO. 17B011-06), the Project funded by China
Postdoctoral Science Foundation (Grant NO. 2016 M590514, NO.
2018 T110568), and the Changzhou Sci and Tech Program (Grant NO.
CJ20179022).
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