SA Head Office: Branches:

Metso House Vereeniging: Tel (016) 430 7200

ACSA Park Rustenburg: Tel (014) 538 0211
Jones Road Phalaborwa: Tel (011) 781 7160
Jet Park Katu: Tel (053) 723 2334
Tel: (011) 961 4000 Isithebe: Tel (032) 459 6900
www.metso.com

Size Control 3. Size Control by Methods

1. Introduction In mineral processing practices we have two methods dominating

size control processes:
With size control we understand the process
of separating solids into two or more products • Screening using a geometrical pattern for size control.
on basis of their size. This can be done dry
or wet.

As mentioned earlier neither crushers nor

grinding mills are too precise in their size
reduction job and a lot of size fractions are
misplaced. By using optimum size control
the result can be improved both regarding
capacity, size and particle shape.

2. Size Control by Duties

To prevent undersize in the feed from

blocking the next size reduction stage
(scalping). • Classification using particle motion for size control.

To prevent oversize from moving into the

next size reduction or operation stage (circuit
sizing).

To prepare a sized product (product sizing)

1
 SA Head Office: Branches:
Metso House Vereeniging: Tel (016) 430 7200
ACSA Park Rustenburg: Tel (014) 538 0211
Jones Road Phalaborwa: Tel (011) 781 7160
Jet Park Katu: Tel (053) 723 2334
Tel: (011) 961 4000 Isithebe: Tel (032) 459 6900
www.metso.com

4. Screens

Performance of screens will fall back on three main parameters:

Motion – Inclination – Screening Media

4.1 Screen Motions

4.2 Screening by Stratification 4.3 Screening by free fall

By building up a material bed on a screen deck the material will If we use the double inclination used for stratification (from 10-15
stratify when the motion of the screen will reduce the internal up to 20-30 degrees) we are in free fall, meaning that no particle
friction in the material. This means that the finer particles can layer can build up on the screen deck. The particles will now be
pass between the larger ones giving a sharp separation. sized directly via the screening media, giving a higher capacity,
(or a more compact installation), but also less sharpness in
separation. Optimal use when a large amount of fines shall be
removed fastly.

2
 SA Head Office: Branches:
Metso House Vereeniging: Tel (016) 430 7200
ACSA Park Rustenburg: Tel (014) 538 0211
Jones Road Phalaborwa: Tel (011) 781 7160
Jet Park Katu: Tel (053) 723 2334
Tel: (011) 961 4000 Isithebe: Tel (032) 459 6900
www.metso.com

5. Screen Types

There are many types of screens, but they can be reduced to the
four types shown below. Of these types approx.80 % used world-
wide are of type single inclination, stratification screens. The
other are of type double, triple or multiple inclination, where
screening by stratification and free fall are combined for different
applications.

Single inclination Triple inclination

• Stratification screen • Combine capacity and

• Circular (15 deg.) selectivity
• Linear 0-5 (deg.) • Typical control screen
• Still the leader in for advanced product
selective screening fractions

Double inclination Multiple inclination

(’’banana screen’’)
• Free fall
• Compact. high • Effective ”Thin-layer”
capacity paid for by screen
lower selectivity • Popular in coal and
• Typical in circuit metallic mining
screening

6. Screen Capacities

Sizing of screens is a time consuming process to be done by

specialists. To get an idea about capacities we can use the figures
below. They refer to screening by stratification using wire mesh
as screening media.

Example

Single deck screen. Feed size 50% - 2 mm.

Feed capacity 90 t/h, cut 2 mm

select: a 10 m2 screen deck.

3
 SA Head Office: Branches:
Metso House Vereeniging: Tel (016) 430 7200
ACSA Park Rustenburg: Tel (014) 538 0211
Jones Road Phalaborwa: Tel (011) 781 7160
Jet Park Katu: Tel (053) 723 2334
Tel: (011) 961 4000 Isithebe: Tel (032) 459 6900
www.metso.com

7. Selection of Screening Media Wire mesh panels offer superior open area and are quickly
available.
Selection of the correct size and type of screen is important.
Equally important is the selection of the screening media. This
refers not only to a correct aperture related to the ”cut size ”,
but also to the wear in operation of these screens. Below a short
selection guide to screening media can be found.

Rubber or Polyurethane?

Feed size Select Because

>35 mm dry Rubber 60 sh • Absorbes impact
• Resistant to sliding
abrasion
<0-50 mm wet Polyurethane • Very good against Bolt down panels, pre-tensioned for easy installation and
sliding abrasion guaranteed screening performance.
• Accurate separation
<40 mm dry/moist Rubber 40 sh • Very flexible
(soft) • Prevents blinding
Look out for:
• Oil in rubber applications
• Hot water or acids in PU-applications

What thickness?

General rule for min. thickness:

Panel Thickness = Max feed size/4

Self supporting panels, for screens of open frame design
What happens if we go...? for tough applications .

+ Capacity _
+ Accuracy _
_ Service life +
_ Blinding/Pegging tenancy +

N.B.: Thickness should not exceed required product size

Modular systems provide flexibility in wear material/hole
What type of panel? configuration combinations.

Tension mats with hooks fits all screens designed with cambered
decks and tensioning rails.

4
 SA Head Office: Branches:
Metso House Vereeniging: Tel (016) 430 7200
ACSA Park Rustenburg: Tel (014) 538 0211
Jones Road Phalaborwa: Tel (011) 781 7160
Jet Park Katu: Tel (053) 723 2334
Tel: (011) 961 4000 Isithebe: Tel (032) 459 6900
www.metso.com

What hole size? (Inclined deck) What type of hole?

General guideline for

The standard choice
wire mesh:

“Required product size

plus 5 – 10%”

For improved service life

(coarse screening)

General guideline for

rubber panels:

“Required product size For improved capacity

plus 25 – 30%”

For improved accuracy and

dewatering

General guideline for

PU panels:

“Required product size

plus 15 – 20%”

Par ticle Size – Mesh or Micron?