Development of A Model For Predicting The Screening Performance of A Vibrating Screen
Development of A Model For Predicting The Screening Performance of A Vibrating Screen
MINERAL ENGINEERING
ABSTRACT
A mathematical model for the performance of a vibrating
screen is developed in terms of an oversize partition curve.
This is a normalized curve for any assemblage of particles
presented for screening when their size is normalized with
respect to the 50 per cent passing size (d50 ) under the prevail-
ing screening conditions. Based on the throughfall aperture
(hT) of the wire mesh on the deck, the effects of oversize
(% > h T), half-size under (% < 0.5 h T), deck location and feed
rate were evaluated using the existing screen sizing informa-
tion. All these variablesand also the near-mesh (1.25 hTx O. 75
h T) content (%) of the feed affect the d50 •
Performance data from different decks of a double-deck
screen with various feed rates, size distributions and screen
apertures were used to evaluate the near-mesh factor. Effects
of wet screening and material bulk density are also incor-
porated in the model. This generalized model is useful for the
simulation of a multiple-deck screen. It furnishes the sieve
,.
FIGURE 1. Photograph of the test screen system.
analysis information of all the deck output streams and
therefore has a potential use in the over-all circuit evaluation
when used in conjunction with relevant crushing and grinding
performance models. An example illustrating the prediction tions, very often a vibrating screen is employed. To be able to
capabilities of the model is given. predict how a screen is going to perform under different feed
conditions, the development of a screening process model is
Introduction necessary. The model will be of great use both in effici ent
Screening is a widely used industrial process for the continuous screen sizing and in simulatio n of closed-circuit crushing. For
separation of materials, based on particle size. For processing the latter purpose, Whiten'D and Mular(2) have developed
coarse particle assemblies, prevalent in the crushing opera- screen models. Both these workers did not use con ventional
screen sizing methodology in their model development.
With Rexnord's role as equipment manufacturer, we were
interested in developing a performance prediction model based
on the existing screen sizing methodology. The idea, of course,
V. K. Karra is to relate it backwards for the development of an efficiency-
based screen sizing method . All efforts were made to keep the
Vijia K. Karra is now a manager, pro- developmental process simple enough for an easy understand-
cess research, after being a senior ing by various levels of screen application people.
research engineer for over 2 years in
the Process Machinery Division of Experimental
Rexnord, Milwaukee, U.S.A. He During 1973, data were gathered from a Nordberg double-
holds a Bachelor's degree in deck 1.52- by 3.66-m GP screen in the Waukesha Lime and
metallurgical engineering from India Stone plant in Wisconsin. It is a two-bearing circle-throw in-
and Master and Doctoral degress in clined screen (20 degrees to horizontal), with an SOO-rpm
materials science (minerals) engineering from the University of motor and 7.9-mm throw. The screen system (Fig. I) was set
California, Berkeley. Prior to his graduate study, he was a senior up for convenient sampling and tonnage mea surements on
scientificassistant for over four years in the Minerals Division of the various streams. Variables tested were as follows :
Regional Research Laboratory, Bhubaneswar (India). His current in- Feed Rate (tph):103 to 299
terests are in the processanalysis and modelling of crushing, grinding Feed Size (mm): 50.8xO, 38.lxO, 25.4xO, 18.8xO
and screening equipment. Mesh on Top Deck (mm sq.): 25.4, 22.2, 15.9
Mesh on Bottom Deck (mm sq.): 15.9, 9.53, 5.41
Keywords: Mineral engineering, Models, Screening, Vibrating
Data on tonnage and sieve analysis of feed, top-deck oversize,
screens, Partition curves, Sieve analysis, Metallurgy.
bottom-deck oversize and bottom-deck undersize were compil-
ed.
80
TABLE 1.
% Cj
r 60
50% Size Interval dl 'F ,1
0
,2
0
,2u ,1u c] c~
(d-x d21 mm (=W21I) 147 lph 27.2 32.7 87.1 119.8 % %
40
37.6x26.7 31.7 .0167 .09 99.72
20 26.7x18.8 22.4 .1129 .55 .05 .0136 90.14 100.0
18.8x15.9 17.3 .1497 .28 .44 .1201 34.61 100.0
15.9x12.7 14.2 .0975 .05 .37 .01 .1083 9.49 93.25
0- L...-_..JIC..._ _--+---':....::...._ _ 12.7x9.53 11.0 .1130 .03 .11 .14 .1318 4.91 22.78
9.53x7.94 8.70 .0600 .03 .09 .0736 11.13
d _ 7.94x6.68 7.28 .0652 .11 .0800
i 6.68x4 .70 5.60 .0948 .16 .1163
4.70x3 .33 3.96 .0830 .14 .1018
(= J (d, d 2 ) j ) 3.33x2 .36 2.80 .0592 .10 .0727
< 2.36 .1482 .25 .1818
FIGURE 3. Basic sbape of an oversize partition curve for a
screen deck. "Superscripts 1, 2 refer to top and bottom decks respectively.
• ·dJo = 18.71 mm, ~ = 12.24 mm
168
\
) ·O-r--------------~
100
U (()~
e, 80 0·8
ill tl
tJ;
o
o
N ....
'ij)
'-
ill
60
s
~ o
o
....g
C
c
.;:; 40 ..:. 0·4
'-
0 R
(lJ
ill
Q. ~
ill
'-
.... 20 ~
C
~
II
0·2
ill
o'- a'
0\'
ill
Q.
0- O-,l'----+----+---+------i---,
0'4 06 0·8 1·0 1·2 1-4
o 0·2 0·4 0·6 0·8 )·'0
(dj/d s O)
relative aperture (dSO/h t )
FIGURE 4. Normalized oversize partition curve.
FIGURE 5. Tbe Interdependence or relative aperture and
screening efficiency: top deck.
Using a multiple regression computer program, this efficiency
can be correlated to K and the percentage of near-mesh
material in the feed, X n , as:
)·0-.-------- - - -- - -- - ---"'7\
efficiency = a (K)b (1- ~)C . . .. . • .. . • . . . . . . .. . . . . . .. . .. (8)
100
Equation 8 permits the development of a near-mesh factor G,
defined as: 0·8
G = a ' (1- ~)c· (9)
100
0 90
_ _ CALCULATED DISTRIBUTION 10
Z o A ACTUAL DISTRIBUTION
'" 80
o
20
'"
~
TOP DECK
w 70 A BOTTOM DECK 30
>
....
«..... 60 40
::l 50 50
:E
::l
U 40 60
~
..
.... 30
TONNAGE
TOP DECK BOTTOM DECK 70
::E: (TPH) I 2 3 4
0 20 OVERSIZE UNDERSIZE OVERSIZE UNDERSIZE 80
w 21 82 49 33
OBSERVED
~ 10 90
CALCULATED 20 83 49 34-
0 -L.---- -+~:......+____4~'_I~I___1I__I_!.-IO(
of oversize, half-size and near-size material in the feed are size and undersize and sieve analysis (see Table 3) are fairly
done using appropriate linear interpolations. For example: straightforward. A similar calculation procedure gives the per-
Q (>14.6) = 6.32 + 14 (15.9-14.6)/(15.9-12.7) = 12.01% formance information for the bottom deck (Table 4). The
R «7 .30) = 7.11 (7.30-6.68)/(7.94-6.68) + 10.74 + over-all information gathered from this simulation procedure
7.42 + 5.68 + 21.47 = 48.81 % is given in Figure 7. Comparison of the experimental and
X, (18.3 x 11.0) = 6.32 (18.3-15.9) / (18.8-15.9) + 14 + calculated values shows fairly good model predictions. Figure
20.42 (12.7-11.0) / (12.7-9.53) = 30.18070 8 shows the performance summary for the 1.52- by 3.66-m
Here, d 50 is calculated from double-deck GP screen with 25.4-mm-sq.-mesh on the top
d50 = hT ( Theo. undersize t Ph/s Q.m)-O.l411 (12) deck and 15.9-mm-sq.-mesh on the bottom deck . Minus
ABCDEFG 50.8-mm crushed stone was fed at 207 tph to the top deck . The
Oversize partition values are calculate using the d 50 in equa- simulation capability of the model is once again fairly good.
tion 10. Once this is done, the rest of the calculations for over-
Conclusions
TABLE 2. Equations for various screen factors The vibrating screen performance model developed by coup-
given in the Reference Manual(9) ling the existing screen sizing methodology with a normalized
oversize partition curve gave fairly good predictions of the
tonnages and sieve analyses of the oversize and undersize pro-
Factor A (for crushed stone) P - opening s ize (mm) = hT
A = 12.1286 (P)O.3162.-10.2991 P<50.8 (12) ducts of a double-deck GP screen processing crushed stone .
A 0.3388 (P) + 14.4122 P~50.8 (13) The model is expected to be of potential value in closed-circuit
Factor B 0 = % oversize in feed to deck crusher simulation work and in the development of an improv-
B -0.012 (0) + 1.6 Os87 (14) ed screen sizing methodology.
B 0.0425 (0) + 4.275 0>87 (15)
Factor C R % half-s ize In feed to deck
C 0.012 (Rl + 0.7 Rs30 (16) TABLE 3.
C = 0.1528 (R)O.564 30<R<55 (17l
C = 0.0061 (R)1 .37 55sR<80 (18
C = 0.05 (R) - 1.5 R~80 (19) TOP DECK
Factor D S = Deck location; top: S =1, Second S =2, etc. Size Feed 0/0
D = 1.1 - 0.1 (S) (20) (mm) (tph) Reporting Oversize Undersize
Factor E for wet screen ing, let T = 1.26 hT to (tph) (tph) (%)
E = 1.0 T<1 (21) Oversize
E T 1 sTs2 (22)
E = 1.5 + 0.25T 2<T <4 (23) 18.8x15.9 6.51 95.86 6.24 0.27 0.33
E = 2.5 4 sT s6 (24) 15.9x12.7 14.42 63.63 9.18 5.24 6.33
E = 3.25 - 0.125T 6<Ts10 (25) 12.7x9.53 21.03 20.27 4.26 16.77 20.27
E 4.5 - 0.25T 10<T < 12 (26) 9.53x7.94 7.05 5.58 0.39 6.66 8.05
E = 2.1 - 0.05T 12sTs16 (27) 7.94x6.68 7.33 2.01 0.15 7.18 8.68
E 1.5 - 0.125T 16<T<24 (28) 6.68x4.70 11.06 0.44 0.05 11.01 13.31
E = 1.35 - 0.00625T 24 s Ts 32 (29) 4.70x3.33 7.64 0.06 a 7.64 9.23
E 1.15 T>32 (30) 3.33x2.36 5.85 0.01 0 5.85 7.07
Factor F U = bulk density (kg/m 3) <2.36 22.11 a 0 22.11 26.73
F =
(U/1602) (31) TOTAL 103.00 20.27 82.73 100.00
170
100- 0
e 90 CALCULATED DISTRIBUTION 10 C
u.I
Z o l:i. ACTUAL DISTRIBUTION Z
Vi 80
V)
o TOP DECK
20 «
~
~
u.I
u.I 70 c: BOTTOM DECK 30 at:
> u.I
>
<
.....
::>
60 40
~
«
.....
50 50 ::>
~
::> s:::J
u 40 60
U
~
~
~
30 TOP DECK BOTTOM DECK 70 &i
TONNAGE ~
J: ( TPH) I 2 3 4 J:
e 20 OVERSIZE UNDERSIZE OVE RSIZE UNDERSIZE 80 o
u.I
OBSERVED 103 104 33 71 u.I
~ 10 90 ~
CALCULATED 98 109 37 72
0 .-100
co /'0.. co /'0.. 00 co
00
('")
('")
('")
0
/'0.. 00 &i r...:
N co .0 ('") 0
N -.i -o 0:
PARTICLE SIZE (mm) ('")
N l£)
FIGURE 8. Comparison of actual and calculated tonnages and sieve analyses for a 1.52- by 3.66-mm DDGP screen witb 25.4- and
15.9-mm-sq.-mesh cloths, respectively, on tbe top and bottom decks. Material: -50.8-mm crushed stone. Feed rate: 200 tph.