Considerations for sizing, selecting vibrating screens

Aggregate producers have plenty of variables to ponder as they plan operations, with sizing and selecting screening equipment undoubtedly part of their many decisions.

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For vibratory screens, producers should pursue answers to a number of key questions before coming to final decisions. They can seek out manufacturers and dealers to help them come to the right solutions, giving some thought to the three questions presented within this article.

Getting started

1. How many decks do you need for a vibratory screen? Vibratory screens can be configured with one, two, three or four decks, with some fine-screening operations having as many as eight decks.

Three decks are pretty common within aggregate operations, but the number of screen decks depends on the number of products a site needs to make. In a typical application where multiple products are being made, the top deck (or decks) of the screen makes the coarse cut, the middle deck (or decks) makes a middle cut and the bottom deck (or decks) makes the fine cut.

Each screen deck is covered with screen media containing openings for particles to pass through. Screen media comes in different forms, and the type of media plays an important role in screening efficiency.

Important consideration

2. What type of screen media is best for your vibratory screen? Screen media is all about open area, or the number of openings in the screen. The more openings in the screen, the more opportunities particles will have to pass through – and the more efficient the screen will be.

Still, more openings in a screen can decrease the wear life of the media. The correct screen media for an application will balance both wear life and efficiency. Common types of screen media for aggregate applications include woven wire, polyurethane, rubber and hybrid.

Woven wire

Woven wire cloth is the most consistent, versatile media product. It averages 50 to 70 percent open surface area in most configurations and provides flexibility for operations that need to make frequent media changeouts due to varying product specifications. Overall, screening efficiency is good with this type of media.

Polyurethane

Polyurethane is better suited for wet or wash screens and dry applications with highly abrasive materials. It provides 30 to 40 percent less open area than wire cloth, but polyurethane offers extended wear life over wire media.

Rubber

Rubber media is used for heavier, coarser materials that can damage standard wire screens. It is most often used for dry applications or abrasive materials. Rubber media has fewer openings than wire cloth, therefore delivering less throughput. It can, however, last much longer than wire screens.

Hybrid

Hybrid media combines a wire screen with reinforced rubber, or urethane strips, to fit screen supports. It is highly popular in dry-screening applications with high-moisture materials and a high proportion of fines.

This type of media works to eliminate blinding and pegging, which forces production to halt in order for a screen to be cleaned. Hybrid media provides more open area than polyurethane and lasts longer than woven wire.

Depending on the application, production can increase 40 percent using hybrid screen media.

Selecting the right screen

Because screening plays such an important role in producing required specifications of a final product, it is imperative that the right screen be selected for every job.

Vibrating screen selection is based on several factors, including maximum tons per hour, gradation of the feed material, type and weight of material, desired size of separation, any surface moisture on material and any special operation requirements, including physical characteristics of the feed or product requirements.

3. How do you size a vibratory screen for an aggregate operation? Vibratory screens come in a variety of sizes. They can range from 4 ft. to 12 ft. wide and 6 ft. to 32 ft. long. The width of the screen determines the carrying capacity of the screen deck, while the length of the screen determines the overall efficiency of the screen. Typically, the length of the screen is two-and-a-half to three times the size of the width.

Every manufacturer has its own screen sizing formula. Screens are tailored to an operation based on a few key factors:

• Basic capacity. How much material is going to pass through a certain opening?

• Incline. How much of an incline, if any, is needed?

• Deck. Not all of the length of the lower decks may be utilized, as material has already traveled down some length of the upper decks before reaching the lower ones.

• Oversize. How much material should go over the deck?

• Half size. How much material is half the size of the media opening? With a high percentage of half size, the probability of material passing through the screen openings will be higher, and the screen will be that much more efficient.

• Slot. How large are the openings in the screen?

• Condition. This applies to both the feed material and the atmosphere around the plant. Is the material wet and sticky? Does it have a high percentage of clay? What is the temperature outside? Is the climate wet or dry?

• Shape. Round or cubical particles have a higher chance of passing through the screen openings than a flat, elongated particle that has to find the right position to fall through.

• Weight. The density of the material matters.

• Open area. The more open area on the screen, the better the chance particles will find an opportunity to pass through.

Takeaways

When sizing and selecting a vibrating screen for an aggregate operation, be sure to provide manufacturers with as much accurate detail about the feed material and the application as possible. From there, manufacturers can recommend which type of screen – inclined or horizontal – is best for a site. They can also recommend a number of decks and type of screen media that will provide the best wear life and efficiency.

Technical Specifications of Vibrating Screens have always been a question for the Ceramic, Tile, and Glaze Industries For owners of ceramic, tile, and glaze industries striving for better product quality, the technical specifications of vibrating screens have always been a matter of interest.

Vibrating screens are essential tools in the ceramic and tile industries, used for separating, classifying, and filtering various materials. These devices play a vital role in enhancing the quality of final products and improving the production process.

Using vibrations, these screens quickly and efficiently sieve materials. Vibrations are typically generated by vibrating motors and transferred to various meshes. Depending on the type and size of particles, vibrating screens are available in different mesh sizes, diameters, and output capacities.

This article reviews the important technical specifications of vibrating screen and key points to consider when purchasing them. Additionally, Mahand Ceramic Industrial Company, as the first manufacturer of circular vibrating screens with European motors and stainless steel mesh and body compliant with health and safety standards, will be introduced.

Key Technical Specifications

Key technical specifications refer to essential details like screen diameter, mesh size, capacity, vibration type, and material composition, which determine the performance and suitability of vibrating screens for different applications.

1. Type of Input Materials for Screening: Liquid and Solid

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• Glaze and Engobe: These materials are liquid and require separation of fine particles and impurities.o Powder: Suitable for separating fine and soft particles. For example, dry tile powder needs screens with fine meshes to maintain the high quality of the final product

•  Clay: Earth materials must be carefully screened to remove unwanted particles.o Granules: Coarse stones and particles need high-strength screens capable of separating coarse particles like tile and ceramic granules.
•  Slurry: In tile, ceramic, tableware, and sanitary ware production, slurries require precise screening to remove all unnecessary particles.

2. Bulk Density of Input Materials: Should be determined based on the physical characteristics of the materials.

3. Required Output Capacity of the Screen (per hour): The screen’s capacity should match your needs based on the volume of materials to be screened.

4. Mesh Size: Customers should determine the desired size in millimeters, inches, or microns and select the code accordingly for each screen layer.

5. Diameter of the Vibrating Screen: Screen diameters can range from 45 cm to 1.5 meters, varying based on the volume of input materials.

6. Special Features and Innovations

•  Cleaners: Dust covers and mesh cleaning systems like ultrasonic systems or cleaning balls.
• Ultrasonic Systems: Devices that use ultrasonic vibrations to separate particles across the screen. These mild vibrations make these devices ideal for cleaning mesh screens.

7. Device Input and Output:

Buyers should specify the type of input needed for the vibrating screen based on their product type. The types of circular vibrating screen inputs include:
Input Types:

Funnel:

•  The most common type of input.
• Conical in shape and evenly distributes materials across the screen surface.
• Suitable for dry or powdery materials.
• An optional lid can control the speed of material input.

 Pipe Line:

•  Used for slurry or liquid materials.
•  Materials are pumped into the screen through a pipe.
•  This type does not provide even distribution of materials across the screen surface.

 No Lid:

• Open input.
•  Suitable for manually added materials.
•  Used when precise control of material input speed is not necessary.

Output Types:

Wide Studs:

•  Comprises several wide studs.
• Screened particles are guided to the screen edges through these studs.
•  Suitable for materials needing separation by different sizes.
•  Offers high output capacity.

Rectangular:

•  Rectangular in shape.
•  Screened particles are discharged through a single output.
• Suitable for materials not requiring size separation.
• Occupies less space.

 Piped:

• Cylindrical shape.
•  Screened particles are transferred to a tank or conveyor through the pipe.
• Suitable for materials directly moved to the next process.
• Requires less space.

 Studs:

•  Comprises several narrow studs.
•  Screened particles are guided to the screen edges through these studs.
•  Suitable for materials needing separation by different sizes.
•  Lower output capacity compared to wide studs.

No utput:

•  No output.
•  Screened particles are collected under the screen surface.
•  Suitable for manually collected screened particles.

Product Diversity of Mahand Ceramic Vibrating Screens for the Ceramic Industry

Vibrating screens in the ceramic industry have a wide variety to meet the different needs of manufacturers. These screens are offered in various mesh diameters to accurately separate ceramic particles. Additionally, multi-layer vibrating screens enable the separation of materials at several different levels.

Other features include single-motor and dual-motor systems, each with its benefits. Single-motor screens are used for lighter applications, while dual-motor screens are used for heavier loads and more stable performance. This diversity in design and structure has made these devices widely applicable in the ceramic industry.

At Mahand Ceramic, you can purchase vibrating screens with this product variety and specific accessories. Our vibrating screens are identified by the following codes:

• VP2s: Circular vibrating screen, dual-motor, for spray dryer and ball mill discharge, and soil separation.
• VLM: Circular vibrating screen for slurry and liquid materials, dehydration, slurry purification, and filtration.
•  GRM: Vibrating screen wagon with magnet and diaphragm pump for the glazing unit.
•  VPM: Circular vibrating screen for granules, used at the end of silos in material and granule production units.
• VAP: Hopper press vibrating screen for installation at press entry and above.
•  VAP2: Dual-motor hopper press vibrating screen for installation at press entry.
•  K3B : Capable of stirring and pumping high-density and high-viscosity liquids.
•  VSB: Circular glaze screen for ball mill and glaze production.

Important Considerations When Purchasing

•  Build Quality: The build quality and materials used in the production of vibrating screens are very important. High-quality devices have a longer lifespan and offer better performance. Mahand vibrating screens with original Italian motors and stainless steel mesh and body, compliant with health and production standards, safety, and excellent after-sales service, are among the best choices.
• Reputable Brands and Manufacturers: Mahand Ceramic, with an active presence at reputable domestic and international exhibitions like the India Ceramic Tile Fair, UNICERA in Turkey, and the Tehran Ceramic Tile Exhibition, has earned a prominent place in the ceramic industry. This company has demonstrated its products and innovations at these events, enabling the exchange of information and experiences, and responding to the needs of domestic and international markets in the best possible way. Continuous participation in these exhibitions shows Mahand Ceramic’s commitment to quality and innovation and its national and international credibility.
•  After-Sales Services and Warranty: Mahand Ceramic vibrating screens come with a 2-year warranty and excellent after-sales services, ensuring you can benefit from support in case of any issues.
• Price and Budget: Setting a suitable budget and comparing prices based on features and technical specifications can help you make the best choice.
  Safety and Maintenance
• Adhering to safety precautions: when using vibrating screens is very important. Regular maintenance and repairs can extend the device’s useful life. Regular cleaning of the mesh and checking the motor and other components is crucial.

Mahand Ceramic, with pride, is the first manufacturer of specialized vibrating screens, maintaining its superior position in the ceramic industry with 40 years of brilliant experience and the best after-sales services.

Frequently Asked Questions About Mahand Ceramic Vibrating Screen Technical Specifications

This section addresses and answers common questions and concerns about the technical specifications and use of vibrating screens.

1. What is the relationship between mesh screen and the type of vibrating screen and the type of products needing sieving?

Vibrating screens are available in various types, including circular, linear, and more. Each type is suitable for separating materials with specific particle sizes. For example, circular vibrating screens are used for dry and powdery materials, while linear vibrating screens are used for liquid and slurry materials. Mahand Ceramic is the first specialized manufacturer of circular vibrating screens with 40 years of experience, leading the industry.

 Mesh screen:

•  A unit for measuring particle size.
•  Indicates the number of holes per square inch of the screen.
• The higher the mesh number, the smaller the screen holes and the finer the particles passing through it.

You can choose the necessary mesh code for your product in the standard mesh screen table on our website.

2. Suitability of Vibrating Screen Type for Industry and Product:

Choosing the right type of vibrating screen for each industry and product depends on several factors, including:

Type of product: What type of material needs sieving (dry, powdery, liquid, slurry, etc.)?

• Particle size: What particle size needs to be separated?
•  Production capacity: How much product needs to be screened per unit of time?
•  Available space: How much space is available for installing the vibrating screen?
•  Budget: What budget is allocated for purchasing the vibrating screen?

 Note: This is only a general guide and may require using vibrating screens with different specifications based on specific industry and product conditions.

What Diameters and Capacities Do Vibrating Screens Have?
The vibrating screen can vary depending on each industry and type of application, and it depends on the specific needs of each industry. However, the selection of a vibrating screen

can be based on the following two main features:

1. Screen Diameter: The diameter of the screen is one of the important factors in selecting a vibrating screen. Different diameters of vibrating screens are suitable for various applications. For example:

 Small Diameter Screens (usually up to 300 mm): Suitable for sieving fine materials like powders and fine granules.
 Medium Diameter Screens (up to mm): Typically used for sieving and sorting relatively coarse materials and medium-sized particles.
 Large Diameter Screens (greater than mm): Suitable for sieving coarse and larger materials like construction materials, sand, gravel, and building stones.

2. Screen Capacity: The capacity of the vibrating screen refers to the production rate and the amount of material sieved per unit of time (e.g., tons per hour). The capacity of vibrating screens is also determined based on the type of industry and its production scale. For example:

• Low Capacity Screens: Suitable for small-scale applications and lower production requirements.
• Medium Capacity Screens: Suitable for standard applications in medium-sized factories and units.
• High Capacity Screens: Used in large industries that require high production rates and robust production lines.

Conclusively, the selection of the type and size of the vibrating screen depends on the type of materials to be sieved, the type of production process, the working environment, and the production requirements of each specific industry.

Conclusion

In this article, we reviewed the important technical specifications of vibrating screens and the key points to consider when purchasing them. Considering the type of materials, the volume of materials, the mesh screen capacity, and the mesh size will help in making an appropriate choice. Additionally, build quality, brand reputation, after-sales services, and budget are factors to consider. Mahand Ceramic vibrating screens, with their outstanding features such as European motors, stainless steel body, and excellent after-sales services, are among the best options for purchase.

For more information and consultation, please contact our experts.

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