Classification of Screen

Screen

Size of
Method of
Material to
Support
be Handled

Coarse, Stationary,
Intermediate Moving
Fine Screen Screen
Classification of Screen

• Stationary screen can be used for both coarse and fine

screening, but mostly for coarse screening as coarse particles drop
easily.
• Moving screens mainly used for fine screening, are agitated
either mechanically or electrically to give linear, circular,
revolving or vibrating motions to the screens
Examples : • Grizzlies • Vibrating Screens • Gyratory Screens •
Trommels
Grizzlies
Construction:
• A grizzly is a grid of parallel metal bars set in an inclined
stationary frame, typically sloped at 30 to 45 degrees.
• Bar length can be up to 3 meters, with spacing between
bars ranging from 50 to 200 mm.
• Bars are constructed using manganese steel to reduce
wear.
• The top of the bars is usually wider than the bottom to
allow for greater depth and strength without clogging by
material.
• Stationary grizzlies are suitable for dry, free-flowing
materials but not for moist or sticky materials.
Working:
• Coarse feed, often from a primary crusher, is introduced
at the upper end of the grizzly.
• Large chunks move downward (tail discharge), while
smaller particles smaller than the bar openings fall
through the grid into a separate collector.
• Increasing the angle of inclination results in higher
output (throughput) but lower screen efficiency.
• Stationary inclined woven-metal screens are used for
particles ranging from 12 to 100 mm in size.
Applications Advantages:
• Grizzlies are most commonly used to • Simple Construction: Grizzlies are
separate undersize (fines) from feed straightforward in design and
to a primary crusher. construction.
• However, wedge-shaped particles • Cost-Effective: They are inexpensive to
can block the grizzly openings. install and require no power for
• Operating a grizzly requires operation.
significant labor, and changing bar • Low Maintenance: Grizzlies have
openings can be challenging. minimal maintenance requirements.
• Grizzlies are primarily used for Disadvantages:
coarse and rough particle • Moisture and Sticky Materials:
separations. Grizzlies face challenges when dealing
with moisture or sticky materials, as
these may cause blockages.
 Trommels
Construction:
• Trommels are revolving screens that are typically
cylindrical or conical in shape, open at both ends.
• They are usually inclined at an angle of 5 to 10
degrees with the horizontal.
• Trommels are slow-speed rotating machines,
with a typical rotation speed of around 15 to 20
rpm.
• Multiple screens with gradually increasing
aperture sizes are arranged along the length of the
cylinder.
• The feed material to be screened is introduced
through a hopper at one end.
Working
• The trommel machine is rotated slowly, either manually or automatically.
• Due to the rotation, particles within the cylinder move downward, and the
screening process takes place.
• Different-sized screens are placed in series, with the finest screen positioned
first and the coarsest screen at the end.
• The feed material is initially introduced to the finest screen. This arrangement
ensures that the coarsest particles are retained on the screen and separated in
later sections, while the finest particles pass through the first section.
• Trommels are designed for separation of coarse particles, typically ranging
from 6 to 55 mm in size.
• Their efficiency depends on factors such as length, diameter, rotation speed,
inclination, screen opening, feed rate, percentage of oversize in the feed, and
percentage of moisture in the feed.
• Trommels are effective for separating larger particles, but they are considered
low capacity and low efficiency machines when used with a single aperture
opening Operating speed of a trommel is 30 to 50% of the critical speed
Arrangement-1:
• In this arrangement, the trommel screens are
set up in a series with the largest perforation
trommel positioned at the top.
• It is the most convenient arrangement for
solid separation purposes.
• With this arrangement, the coarsest particles
are obtained and separated first, making it
efficient for primary separation.
• The finest particles are obtained at the end of
the series, allowing for a progressive
separation of particles from coarse to fine.
Concentric Arrangement of Trommels:
• In this arrangement, trommel screens are
positioned concentrically, one inside the
other.
• As the material progresses through the
concentric screens, the smaller and finer
particles move from the coarsest screen
toward the finest screen.
• This arrangement facilitates a gradual
separation process, with the coarsest
particles being screened out initially, and
the finer particles moving toward the
innermost and finest screen.
Vibrating screen
Working:
• In the case of a single screen, vibrations are applied to
the screen to separate solid particles into two size
fractions.
• Vibrating screens typically consist of three decks.
• Material to be separated is fed to the top screen, and
simultaneously, the screens are vibrated either
electrically or mechanically at a frequency of 1000 to
3500 vibrations per minute.
• Vibrations keep the particles on the screen in motion,
and due to the screen's inclination, oversize material
moves along the screen and is collected separately.
• The undersize material passes through the screen and
is collected.
• With a three-deck screen, four fractions are obtained
as a result of the separation process.
Advantages: Applications
• Quick Cleaning: Can be cleaned quickly and efficiently.
• Low Noise: Operates at a low noise level.
• Easy Assembly: Simple to assemble.
• Wood Processing Industry (Pelletizing)
• Low Maintenance: Requires very low maintenance since • Recycling Industry
there is nothing to lubricate. • Chemical Industry (e.g., Fertilizer, Plastic)
• Fast Screen Change: Allows for fast screen replacement. • Foundries
• High Reliability: Offers high reliability with low power
consumption. • Animal Feed Industry
• Cost-Effective: Provides a good price/performance ratio. • Glass and Ceramic Industry
• Maintenance-Free: Features long-lasting anti-vibration • Mining and Construction Material Industry
mountings, making them maintenance-free.
Disadvantages:
• High Maintenance Costs: The maintenance of screens and
their supporting structures can be costly.
• Low Capacity: May have limited capacity.
• Batch Processing: For heavy-duty operations, batch-wise
processing can be time-consuming.
 Gyratory Screens
Construction of Gyratory Screens:
• Gyratory screens consist of vertically
stacked screen decks within a casing.
• Screens are arranged from coarsest (top) to
finest (bottom).
• Discharge ducts enable fraction removal.
• The casing is inclined at an angle of 16 to
30 degrees from the horizontal.
• These screens generate vertical gyrations
via eccentric shafts and allow adjustments
for gyration speed, throw amplitude, and
tilt angle as needed.
Advantages: Applications
• Low Running Cost: Gyratory screens are cost-
effective to operate.
• Ideal for Multi-Fraction Separation: Suitable • Process Industry: Used in ceramic
for separating materials into multiple processing, pulp and paper mills, paints,
fractions.
• Flexible Range of Application: Versatile and sand, starch slurry processing.
applicable in various industries.
• Food Industry: Applied in screening
• Good Efficiency and Quality of Separation:
Provides efficient and high-quality separation. refined table salt, papaya cubes,
• Easy to Maintain: Maintenance is turmeric pigment, and clarification of
straightforward.
alkaline extracts.
• Low Screen Blinding: Less prone to screen
blinding issues. • Chemical Industry: Utilized for
Disadvantages: screening hydrate lime, classification of
• Large Amount of Floor Space: Requires a polyester beads, and anhydrous
significant floor space footprint.
• Susceptible to Lumps and Agglomerates: Can aluminum chlorides.
be affected by lumps and agglomerates in the
feed material.
 Reference books
• Anup Swain, Hemlata Patra, G K Roy, “Mechanical Operations”,McGraw
Hill Education, 2017.
• McCabe, W.L., Smith, J.C., and Harriott, P., “Unit Operations of Chemical
Engineering”, 6 th ed., McGraw Hill, 2001.
• Brown, G. G., et al, “Unit Operations,” CBS Publishers & Distributors, New
Delhi, 1995