Stack high frequency vibrating fine sizer (stack sizer) is such equipment of which a single driving source drives multiple screen decks to vibrate simultaneously. The effective feeding width of stack sizer is the sum of multiple single screens.
3. Preface
Along with the advances of modern industry, the size of
enterprise is growing. As a result equipment of high efficient,
high capacity and low energy consumption is required. This
also applies to fine sizer, the effective size control equipment
in classification operation. However, traditional fine sizer is a
compromise between classification size and screening
capacity and covers large floor area, which restricts efforts of
enterprise in capacity expansion and efficiency improvement.
The development of stack sizer and polyurethane screen
resolved the contradiction between screening capacity and
precision, and the problem of low area specific capacity of
high frequency vibrating fine screen.
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4. Content
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Introduction of stack high frequency vibrating fine sizer
Characteristics of non-blind
abrasion-resistant urethane
screen
Factors affecting screen
selection
Application case studies Scene photos and user list
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6. 1. Stack High Frequency Vibrating Fine Sizer
Stack high frequency vibrating fine sizer (stack sizer) is such
equipment of which a single driving source drives multiple
screen decks to vibrate simultaneously. The effective feeding
width of stack sizer is the sum of multiple single screens.
In stack sizer up to five screen decks is positioned one above
the other and operating in parallel. Each screen deck
completes separating independently and has separate
undersize and oversize collection pan. The undersize/oversize
collection pans discharge to two common outlet respectively.
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7. Similarities of stack sizer to single deck high frequency vibrating
fine sizer – high frequency and small vibration amplitude
Such vibration is helpful to:
• destruct the surface tension of pulp and the adhesion of fine
particles on coarse particles, and to weaken the
agglomeration of fine particles due to Van der Waal’ force
and electrostatic attraction. This is conductive to loose and
layer material, and cause fine particles to separate and pass
screen.
• accelerates the motion of fine particles, especially the dense
valuable ore particles. This increases the probability of fine
particles to contact and pass the screen, and promoted the
classification.
• minimize and prevent screen aperture block, and improve
separation efficiency
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8. Two vibrating motors supply the
vibratory action for all five of
the screen decks. This high
frequency vibratory motion is
uniform throughout the entire
width and length of each of the
screen decks.
The use of dual vibrating motors
creates a linear vibratory action
by which an acceleration of
7.5G is discharged on particles.
2. Mechanism of Stack Sizer
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9. Once the thin layer of slurry is introduced to the screen
surface, the slurry is accelerated by the linear vibratory
force.
This acceleration extends the effective fluidized zone of the
mineral slurry, which enhances the separation over a larger
area of screen surface.
The linear motion also conveys the screened oversize
material out of the way of oncoming feed slurry so that
more open screen area is available for the oncoming feed
and classification efficiency is improved.
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2. Mechanism of Stack Sizer
11. 1)Big screen area specific capacity
Practical production indicated, when iron ore concentrate is
treated:
area specific capacity is 9-10 t/m2·h at screen aperture 0.15 mm
area specific capacity is 8-9 t/m2·h at screen aperture 0.10 mm
area specific capacity is 6-8 t/m2·h at screen aperture 0.08 mm
Area specific capacity of stack sizer is 1.5-2 times of single
Electromagnetic vibration sizer
2) Big floor area specific capacity
Stack sizer has greatest capacity at the same floor area coverage
comparing to other vibrating fine sizers. One 5-deck stack sizer is
able to replace 3-6 single deck vibrating fine sizers.
At the same capacity stack sizer saves 1/3 floor area.
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12. 3) Patented repulping system improves the
capacity and quality of screening
Spray water is directed at
repulping troughs located
between the two panels
on each screen deck.
Repulping system removes
fines from oversize to
maximum extent.
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13. 4) One pair of motors provides a uniform high frequency
linear motion throughout the entire volume of all screen
decks. This cannot be realized by electromagnetic
vibrating sizer.
5) Screen frame surfaced by polyurethane, extending
machine life significantly
Surfaced by special modified polyurethane abrasion-
resistant compound imported from US; not only
anticorrosive but also abrasion-resistant. The abrasion
resistance is 10-15 times of carbon steel. Life of Hot stack
sizer is +8 years.
6) Low energy consumption (single machine power draw
4.5kW)
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15. 1)long life and abrasion-resistant
• Polyurethane elastomer, well known as “super abrasion-
resistant material” and “liquid steel”, is a new synthetic
material between rubber and plastic, with strong abrasion
resistance, wide hardness range, high elasticity and tear
strength.
• Therefore, polyurethane screen has a very lone life, which is
usually several or several tens times of conventional woven
wire screen. Generally the life of polyurethane screen is
above 6 months, and can be up to 10 months in non-ferrous
mine.
1. Characteristics of Polyurethane Screen
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16. 2) Non blind aperture
• The high elasticity of
polyurethane prevents HOT
stack sizer from the adhesion
of moist fine particles,
ensuring the screen surface to
be non-blind with near size
particle. This advantage
effectively compensates for
the slightly lower open area of
polyurethane screen and gives
it high classification efficiency.
• The inverted triangle cross-
section of aperture resolved
the problem of aperture blind
both in theory and practice.
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17. 3) High open area and area specific capacity
Wire diameter down to 0.18mm and open
area up to 35%. Open area same to Derrick
when aperture size is +0.15mm; only 3% lower
than Derrick when aperture size is -0.15mm.
4) Energy Saving
The light weight and low dynamic load of
screen not only minimize power draw and
increase capacity of stack sizer, but also lead to
improved efficiency, reduced machine running
noise and improved working environment.
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18. 2. Analysis of Panel Life and Anti-blocking
Three important indicators for screen performance:
• Open area
• Aperture size
• Panel life
The life of screen panel is proportional to its wire cross section
area. Bigger wire size gives longer life but smaller open area and
capacity. On the contrary, smaller wire size brings bigger open
area and higher separating efficiency but shorter life. Short
panel life requires frequent maintenance and improves costs.
Our screen panel wire size can be as fine as 0.18 mm but usually
is 0.21 mm. Panel life is above 6 months and up to 10 months for
non-ferrous ore.
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19. The life of polyurethane screen relates to its abrasion
resistance and wire size. Generally, harder material has
better abrasion resistance. But this rule does apply to
polyurethane screen which is highly elastic.
In addition, the softer the screen wire is, the larger the
deform of panel is and the harder to block screen
aperture. Therefore, the 3 factors panel material, wire
size/open area and hardness should be taken into
account synthetically to ensure the performance of
screen.
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21. The selection of screen has to consider:
1) Screening size and flowsheet
2) Feed slurry flow rate and solid flow rate
3) Target size fraction content in feed
The higher the target fine size fraction content in feed,
the bigger the screen area specific capacity is. Usually is
70-75%
4) Fines in oversize
Fines in oversize should be minimized and usually is 1/3
of that in feed. For Tin, tungsten poly-metallic ore it is
required to be ¼.
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22. 5) Near size particles in feed
When near size particles content is high, screen area
should be larger.
6) Selection of screen panel
Both of the material and tension of screen panel affect
the capacity, efficiency and cut size of sizer.
Stainless steel woven wire panel should select larger
aperture size (usually 1.73 times)
Polyurethane bar screen panel should select smaller
aperture size (usually 1.5 times)
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24. Typical Applications and Benefits
1) Application of stack sizer in tin polymetallic mine
2) Application of stack sizer in molybdenum
polymetallic mine
3) Replace nylon fine sizer and spiral with HGZS-55-
1207 stack sizer in secondary grinding classification
for iron ore
4) Application of HGZS-55-1207 stack sizer in Panxi
vanadium-titanium magnetite grinding circuit
5) Replace electromagnetic sizer with stack sizer in
Chengde
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25. 1) Case study of stack sizer in a tin polymetallic mine (Guangxi
Province)
Problem: Cassiterite is over ground but sulphide ore less ground
Solution: application of HGZS 3 decks stack sizer as classification
equipment
Changes: %+0.15mm reduced from 36.36 to 29.22, %-0.074mm
increase from 49.18 to 54.87; Benefits: Recovery of Sn and
Pb are improved by 5% and 7% respectively.
Result: More than 30 HGZS stack sizers are applied in different
tin polymetallic mines.
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26. 2) Case study of stack sizer in a molybdenum
polymetallic mine (Inner Mongolia)
Problem: over ground Molybdenum ore, low
concentrate grade and recovery
Solution: application of two HGZS 5 decks stack sizers
as classification equipment
Benefits: throughput increased from 1300t/d to
1500t/d, recovery improved by 76% and 79%
respectively.
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27. 3) Case study of replace nylon fine sizer and spiral with HGZS-55-
1207 stack sizer in secondary grinding classification for iron ore
stack sizer (Aoniu iron ore mine, 2009)
Problem: spiral and high frequency nylon fine sizer used in
secondary grinding have problem of low classification efficiency,
low capacity, being unstable and over-ground problem
Solution: replace spiral and nylon sizer with HOT HGZS-55-1207Z
stack sizer
Changes: Classification efficiency reached 75%, -200 mesh in
oversizer lower than 8%, circuit capacity increased by 15%;
polyurethane panel life was 6+ months, which reduced cost of
maintenance
Benefits: iron concentrate production increased by 14.5% .
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28. 4) Case study of HGZS-55-1207 stack sizer in Panxi vanadium-
titanium magnetite grinding circuit (An Steel Group Midi
Operation)
Problem: Along with the mining of deeper block, ore grade is
decreasing. To keep product the throughput has to be increased.
Background: Two kinds of high frequency fine sizers were used
in Midi, namely GPS sizer and Derrick sizer.
Solution: replace the two GPS sizers with HOT HGZS-55-1207Z
stack sizer.
Result: Comparison indicated that the efficiency of HGZS stack
sizer is approaching to Derrick sizer. When -200 mesh in feed is
30%, the percent of -200 mesh in undersize is 60%. The life of
Hot screen panel is similar to Derrick (4+ months), but the price
is only half. Hot stack sizer brings >40M RMB to Midi operation.
Over 130 Hot stack sizers were installed in the same mining area.
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29. 5) Replace electromagnetic sizer with stack sizer in Chengde
Jianlong Company in Chengdu city installed two HGZS-55-1207Z
stack sizers in May of 2012 preliminarily. After 1.5 months of
operation, the overgrinding of iron concentrates were minimized
and mill capacity was increased by 30%.
Based on this result, all the previous 26 single deck
electromagnetic sizers were replaced by Hot 5 decks stack sizer.
As a result of mill capacity increase, 1 of 3 ball mill became spare
mill. In addition to the 30% mill capacity increase, the moisture
of iron concentrates is reduced by 2%.
Comparison of stack sizer and electromagnetic sizer is as below:
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43. List of Part of Users
User Product Model
Num
ber
Date Ore
广西阳光大地
矿业公司
Stack sizer
HGZS-55-
1007Z
4
2008.
7
Tin
polymetallic
Drum magnetic
separator
HCT-1018NB 4
Tin
polymetallic
江西新海矿业
公司
Stack sizer
HGZS-12-
1210N
12
2007.
1
Tin
polymetallic
江西省金龙矿
业公司
Stack sizer
HGZS-12-
1210N
26
2007.
3
Tin
polymetallic
江西省恒鑫矿
业公司
Stack sizer HGZS-12-1210 4
2007.
5
Tin
polymetallic
湖南省湘成矿
业
Stack sizer HGZS-12-1210 4
2006.
8
Tin
polymetallic
云南个旧老厂
锡矿
Stack sizer
HGZS-33-
1207Z
4
2006.
8
Tin
polymetallic
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