Derrick screens raise potash and phosphate recovery ...

0.50 mm Potash Screening, Chile - (9) 5-deck Stack Sizers.

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In late , three five-deck high-capacity stack sizer® screens fitted with 850-micron Polyweb® screen panels will be installed in australia for sulfate of potash recovery. this will be the first installation of stack sizers for this application in australia. these highcapacity, small footprint screens will produce significantly higher yields than the previous equipment used in the application, allowing recovery operations to focus on capturing as much product as possible with minimal additional work. Derrick&#;s unique Polyweb urethane screen panels on the stack sizer reduce near-size blinding to maintain optimum efficiency, while offering unmatched panel life. Working together with global potash producers to improve mill recovery and efficiency, Derrick continues to develop proprietary high-capacity, high-efficiency, robust and reliable screening solutions for the potash industry. the Derrick stack sizer replaces conventional high-amplitude horizontal banana-type screens before the screening surface. Compared with the low-screening efficiency of conventional screens, the stack sizer offers lower circulating loads, low structural maintenance costs, and reduced brine spray on the screen deck to liberate fines, thereby raising productivity and process efficiency.

In early , Derrick introduced its latest screening innovation, the superstack® to the world and it soon caught the attention of the potash industry. With its eight vibrating screen decks operating in parallel, combined with a 30 to 35 per cent increase in effective screening width compared with Derrick&#;s 5-Deck stack sizer, this novel machine exceeds the stack sizer&#;s capacity by two-and-a-half to three times.

SuperStack enters South Africa

In , Derrick-africa recommended 10 5-Deck stack sizers to a major phosphate producer to upgrade their plant, but were not considered purely on price. In early , Derrick re-attempted to enter the phosphate market by offering superstack screens instead of stack sizers. once again, the offer was rejected due to uncertainty of the new technology. In January , however, Derrick re-visited the producer in Cape town and offered them four superstacks instead of 10 5-Deck stack sizers. they showed that the superstacks would result in significantly reduced infrastructure. through a cost-benefit analysis, Derrick&#;s offer won the $2.3 million tender, allowing the first superstack installation to proceed in africa.

Michelle lawrence, Coo, kropz says, &#;the four superstacks offer an elegant and cost-optimized solution to increasing throughput of the milling circuit and top-size presentation to the flotation circuit. We look forward to recommissioning the plant

and working together with Derrick to maximize overall efficiencies.&#;

the superstack&#;s demonstrated safety and maintenance, environmental, and societal benefits include:

Safety and Maintenance

&#; Totally enclosed, lubricated-for-life vibratory motors &#; Lightweight, easy-to-install screen panels &#; Front-to-back screen panel tensioning reduces changing time to less than one minute per panel &#; Exceptionally low maintenance requirements

Environmental

&#; Low, 10 HP power consumption &#; Sacrificial, replaceable anodes help prevent corrosion on the live frames in the harsh potash environment &#; Stainless-steel support structure and porcelain-coated screen frame construction for long-term durability &#; Reduced infrastructure

Societal

&#; Maximum efficiency in recovery and improved grade to ultimately increase crop yields

Stainless-steel version of SuperStack for potash/ phosphate.

SuperStack in phosphate recovery

Phosphate recovery applications have opened new opportunities for both the superstack and stack sizer screens in south africa and florida in the U.s. In florida, five stack sizers have replaced Derrick Multifeed screens for a long-term (30+ years) Derrick customer. this firm concluded that the time was right to upgrade their operation to the latest proven Derrick technology.

The future of SuperStack in potash/phosphate industry

through successful installations, the superstack is demonstrating efficiency and cost savings in the recovery of potash and phosphate. successful installations are expected to rise as its reputation expands, making it an important element in serving the ever-expanding need for these vital agricultural products throughout the world.

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for more information, contact: amit Jain Mining & Industrial Division Derrick Corporation :

Principles of Operation &#; SuperStack.

General widespread interest in fine coal cleaning circuits did not occur in the United States until the mid &#;s. Up until this period the relatively low price for which bituminous coal was sold did not justify for many operators the capital and maintenance costs associated with the beneficiation and drying of fine coal. However, with current growing interest in this area, the introduction of new types of process equipment along with modifications to existing components is occuring to maximize the recovery of coal fines.

The sandwich screen consists of two independent fine, square, woven wire screens held together in a common binding in such a manner as to allow cross wires of the bottom surface to create an interference in the free openings of the top screen. By adhering to correct opening vs. wire diameter ratios the blinding of nearsize-oversize particles experienced with conventional fixed opening woven wire and profile screens may be prevented. Product separation is thus achieved when fine particles pass through a nominal opening created by cross wires from both fine screen surfaces.

Feed to the machine is via a three way flow divider mounted on a supporting tower above the live frame body. The device is specially constructed to provide uniform feed streams to distribution boxes located at the head of each screen section. Also, a single high speed ( RPM) vibrator is mounted in the center of the live frame which aids the sizing process by rapidly breaking fluid surface tension at the screen surface and conveying oversize solids away from the oncoming load.

Multifeed screens are also currently being used in 28 mesh x 0 fine coal dense medium circuit applications. Screen oversize is reslurried and passed through double drum magnetic separators for further recovery of magnetite values. Similarly, on the clean coal side heavy medium cyclone overflow reports to six units for magnetite drain screening at 150 mesh. Screen underflow returns to the dense medium sump while oversize is reslurried and fed to double drum separators. Finally, 28 x 100 mesh clean coal from the magnetic separators is prethickened on four additional. Multifeeds before discharging into screen bowl centrifugal dryers.

Efficient desliming of 28 mesh x 0 raw coal is of obvious importance in this circuit since recirculation of excessive non magnetics back to the dense medium sump with drain screen effluents will adversely effect system performance. Also of importance is highly efficient removal of fine magnetite through the clean coal and refuse drain screens. By maximizing recovery here magnetite losses are reduced and the job for the magnetic separators is made easier.

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