Major Wire Industries, Inc.

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Major Wire Industries, Inc.
Presentation 104, March 2006
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Inefficient Screening Costs You Thousands Of
Each Year.
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Screening Is The Process Of Sorting Various Sizes
Of Aggregate On A Screen Deck.
Top deck 1 clothMiddle deck 1/2 clothBottom
deck 1/4 cloth
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• 1 ½

• ½ ¼

• ¼

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If A Screen Was 100 Efficient?
100 of the aggregate or slag would be sorted.
However, many things prevent this. Two of the
worst are BLINDING PEGGING.
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Blinding Can Reduce Screen Efficiency By 70 Or
More. Making An 8x20 Screen Deck Into A 4x12.
All metal self-cleaning wire with a 3/8
opening and stainless steel wire in a sand
gravel application. Blinding after one 5-hour
shift.
Slotted wire in a limestone application after
just 2 hours.
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Pegging - Where The Stone Becomes Wedged Into
The Screen Cloth. Can Have The Same Effect As
Blinding Cause Inefficient Screening.
Slotted tempered wire in a sand gravel
wash plant. In operation for just three 8-hour
shifts.
Square opening stainless wire in a crushed
limestone application - 80 pegged after 4 hours.
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Some Applications Have Pegging That Leads To
Blinding Double Trouble!
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The Costs Of Inefficient Screening From Blinding
Or Pegging.

• Lost Production

• Poor Product Quality

• Complicated Process Add-Ons

• Effects On Other Equipment

• Labor Costs

• Lost Income

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Lost Production

• Lost production due to shutdowns to clean screens.

• Lost capacity due to blinding and reduction of
  open area on the screen deck.

• Lost production due to inefficiency.

• Lost production due to product size material
  circulating in closed-circuit loops.

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Poor Product Quality

• Products out of spec.

• Penalties fines.

• Cost to re-screen products.

• Inconsistent gradations cause asphalt/concrete
  mix design problems.

• Products meet only lower grade requirements (low
  selling price).

• Producer loses customer to competitors that can
  maintain high product quality.

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Effects On Other Equipment

• Erratic crusher power draw increased
  fuel/electric costs.

• Difficult to optimize crusher operation (manually
  or by computer).

• Increased wear costs and poor wear patterns (cone
  liners, impactor blow bars, etc.) due to high
  re-circulating loads or from feeding fines to
  secondary or tertiary crushers.

• Extreme inefficiencies can cause crusher
  mechanical/structural problems.

Inefficiently screened fines being sent to
secondary cone crusher.
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Labor Costs

• Cost to clean and change out screens.
• Time spent cleaning shut-down screens could be
  used for more important jobs like operating the
  crushing plant!

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Inefficient Screening Costs You Thousands of
Each Year.
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What Product Can

• Eliminate inefficient screening?
• ? Improve product quality?
• ? Increase plant production?
• ? Reduce your cost per ton?
• ? Make you a hero?

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Flex-Mat Type Self-Cleaning Screens Can

• Eliminate blinding pegging.
• Make screens more efficient by increasing open
  area on each deck.
• Increase plant production rates.
• Improve product quality by removing retained
  fines (overs).
• Reduce the cost per ton to produce aggregate
  products.

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Why Do Flex-Mat Type Self-Cleaning Screens Work?

• Flex-Mat is not a woven wire product.
• With no cross wires, Flex-Mat is able to vibrate.
  
• Vibration allows the screen to shake off dust
  mud or eject pegged stones.
• The urethane cross strips, screen deck crown and
  tension prevent Flex-Mat from passing oversize
  material.

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ConfigurationsFlex-Mat Type D

• The most commonly sold Flex-Mat type - 67 in
  2005.
• ?Provides an accurate passing product to meet
  gradation specs.
• ?Replaces square opening woven wire.
• ?Now available in openings of 3/64 up to 4.

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Flex-Mat Type S

• ?The second most commonly sold Flex-Mat type -
  21 in 2005.
• ?Use where you need to remove a large amount of
  fines.
• ?Use to replace slotted wire (not harp wire or
  piano wire).
• ? Retained material will be clean, quality stone.
• ?Passing material will have some oversize, but
  less than long slot cloth.
• ?Available in openings of 3/64 to 2.

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Flex-Mat Type T Heavy-Duty Applications

• ?Use in high-impact areas or where you have heavy
  bed depth.
• ?Rule of thumb 25 of material is 4 or 5 times
  the opening.
• ?Straight wire is larger diameter and does not
  stretch.
• ?Available in openings of 5/16 to 2.

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Flex-Mat Type T Fine Screening

• ? Use for fine screening applications.
• ? Available in openings of .015 to ¼.

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LFM

• ?Major Wires solution to a better Harp or piano
  wire.
• ?Wear life of 3 to 4 times longer no moveable
  metal crossing.
• ?Wire size can be customized to meet each
  application - limited to 2 sizes with Harp
  piano wire.

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Importance Of Screen Open Area.
More holes.

• Flex-Mat 3 can increase production rates,
  eliminate bottlenecks and reduce the cost per
  ton.
• ? Flex-Mat 3 has 15 to 30 more open area than
  equivalent square opening woven wire screen
  cloth!

More chances for material to fall through!
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Importance Of Screen Open Area.

• Open area is directly related to screen capacity.

• Every chance an undersized particle has of
  contacting a screen opening increases the
  probability of the particle passing through.

• A Flex-Mat 3 screen with 10 more open area than
  woven wire will potentially have 10 more
  capacity.
• Any blinding or pegging reduces screen capacity
  example losing 10 of the screen openings
  decreases the screen capacity by 10.

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Relative Open Area Comparisons On A 6x20
Screen Box.
Flex-Mat 3 D or T Open Area
Polyurethane Open Area
Flex-Mat 3 S Open Area
Total Area Of Screen Box
Woven Wire 20 Blinded Open Area
Woven Wire Open Area
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Open Area Comparisons
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RESULTS Eliminated Blinding, Screening In
Missouri.

• Customer was using ¼ opening SS .092 square
  opening woven wire on bottom deck.
• Blinding reduced capacity, caused frequent plant
  shut downs, made retained stone dirty.
• Flex-Mat D SS .072 wire eliminated blinding
  increased plant capacity.
• Shut downs were eliminated, material
  specification improved as it was cleaner.

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RESULTSEliminated Blinding, Screening In
Nevada.

• Customer had severe consistent blinding problem
  screening caliche.
• Plant was being shut down daily to clean screens.
• Flex-Mat D SS 3/16 opening with .054 wire was
  installed as a test.
• Photo shows woven wire and Flex-Mat on same
  screen deck after 6 weeks.

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Woven Wire Unique Solutions

• Introduced
• Double-Weave.
• Handles high impact better.
• Offers more open area than punch plate.
• Longer wear life than single wire cloth.

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Woven Wire Solutions

• Now offer
• HyperSlot Long Slot
• - Alternating crimped wire retains material on
  deck longer.

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HyperSlot

• Great for de-sanding or removing large amounts of
  fines.
• ? Major Wires unique design offers 3 benefits
• Crimped wires tend to slow material down so that
  it has more chance to come in contact with
  openings in the screen cloth.
• Crimped wires tend to roll the material, which
  does a better job of removing fines.
• With alternating crimped and straight wires, the
  screen cloth does allow for some vibration.
  This improves the products ability to reduce
  blinding in comparison to all straight wire
  slotted cloth.

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Single Triple Shute Slotted Cloth

• Typically used where blinding is a problem.
• Does allow oversize material to pass.

• Common before the introduction of self-cleaning
  screens.
• ? Should not be used where precise sizing is
  required.

Single shute normally up to 1
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Major Wire2005 Re-Qualified For ISO 90012000
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THANK YOU!