Screening Solutions by Screening Specialists

Transcription

1 Screening Solutions by Screening Specialists

2 Introduction Founded in 1930, W.S. TYLER CANADA operates a Screening Media (TYLER) and a Vibrating Screen Division (TYCAN) under one roof for over 75 years. The company philosophy is to provide Screening Solutions by Screening Specialists. Today, W.S. TYLER CANADA is part of the family owned Haver Group and the only company in the world capable of supplying all aspects of the renowned screening circle. The screening circle is a given necessity for any customer that aims to separate his products according to size. The screening circle contains the following components: W.S.Tyler Canada TYCAN 4. Service: The screening media and the vibrating screen must be defined as a complete screening system. TYCAN understands that responsibility and as a result offers far reaching services, such as the self developed vibration analysis. Using such milestone technologies we are today capable of ensuring complete synchronization between screening media and vibrating machine with the help of automatically generated improvement recommendations. To ensure the quality of the recommendation results, we again require the particle analysis and thus the screening circle closes to form a complete rotation. 1. Particle Analysis: the basis for any screening process is the understanding of the size distribution within the feed material as well as the desired product. TYLER offers all aspects of particle analysis, beginning with standard sieves over traditional laboratory shakers such as the famous ROTAP to the technology of Computerized Particle Analysis (CPA). The Screening Circle 3. Vibrating Screens: The particle sizes of the feed material as well as the required cut sizes determine the necessary drive technology and physical size of the vibrating screen. TYCANʼs engineering department is a very international team. As a result the customer benefits from this wide range of experience and process studies with screening solutions that are extraordinary and unprecedented in the history of the screening industry. Using tools such as FEA and 3-D CAD systems, TYCANʼs promise is to develop customized solutions according to product application and customer specification. 2. Screening Media: The results of the particle analysis and the material characteristics determine the opening and the composition of the screening surface. TYLER offers a full line of screening media, starting with woven wire cloth, engineered rubber and polyurethane systems to self cleaning screens and perforated plate. TYLER understands the impact media changes can have on protecting the vibrating screen itself. For planning, designing, engineering and manufacturing complete Screening Solutions, W.S. TYLER CANADA is always the right partner. Our decades of experience in providing all aspects of the screening circle ensure that you are receiving: Screening Solutions by Screening Specialists 2

3 Eccentric Shaft Systems (4-bearing Technology) The N- CLASS The TYCAN N-Class is commonly used as a primary screen targeted at increasing the throughput and the efficiencies of the primary crusher in very heavy duty and aggressive environments. Capable of handling particles as big as 78 x 39 x 39 and screening at cut sizes of ½ to 12 it is ideal for very demanding industries such as mining or crushed stone. This operation principle consists of the use of a shaft and four bearings. The vibration motion is worked into the shaft in form of single eccentricity, allowing for equipment operation with consistent amplitude, independent of the load fed to the screen. Due to the constant dynamic operating conditions and consequently the very high G-Forces generated by the technical principle of the vibrating screen, product particles are consistently launched out of the classification openings of the media creating a self-cleaning effect, which minimizes material clogging and pegging. N-CLASS in a typical layout PRINCIPAL CHARACTERISTICS: Consistent amplitude Constant dynamic, load independent operating conditions, Adjustable frequency Dry and humid classification Cuts of up to approximately 12 High classification capacity and better classification efficiencies Use of perforated plates up to 4 with conical opening as classification media Allows for various classification deck configurations Allows for the classification of viscous and sticky products Does not transmit vibrations into the structure Width of up to 8 ft. Length of up to 22 ft Optional full or partial dust enclosure Allows for immediate stoppage (either by electric brake or by reversal) eliminating residual vibrations N-CLASS Scalper screen Model ESS 2400 x

4 Double Eccentric Shaft Systems (4-bearing Technology) The F-CLASS The TYCAN F-CLASS is the number one vibrating screen for classification in the heavy mining, mineral and crushed stone industries. The positive circle-throw motion of the F-CLASS is developed by a counterbalanced double eccentric shaft, which is supported by four double spherical roller screen bearings. Rubber mounting units dynamically balance by isolating the vibrating body from the stationary base frame. The shaft is supported on the base by side arm assemblies that are also isolated on rubber mounting units. The F-CLASS free floating action permits the shaft to find its natural center of rotation without strain or thrust on the bearings. This feature minimizes maintenance and downtime and prolongs the life of the bearings. TYCAN F-CLASS in a typical layout PRINCIPAL CHARACTERISTICS: Consistent amplitude Constant dynamic, load independent operating conditions Adjustable frequency at speeds of 750 to 1050 RPM Dry and humid classification Solid HUCK bolted construction Hands Free tube housing assembly for easy bearing exchange Allows for various classification deck configurations of up to 3 decks Allows for the classification of viscous and sticky products Does not transmit vibrations into the structure Installed at angles of 15 to 25 degrees Width of up to 8 ft (2500mm) Length of up to 24 ft (7500mm) Optional full or partial dust enclosure Optional ball tray for classification of fine and sticky material F-CLASS model 900 Counterbalanced double eccentric shaft assembly 4

5 Concentric Shaft Systems (Two-bearing Technology) The T-CLASS The TYCAN T-CLASS vibrating screen with field proven features makes it a versatile performer. It is designed to be a rugged dependable vibrating screen for use in the screening of a wide variety of materials. The circle throw motion of the T-CLASS Series is developed by a counterbalanced shaft assembly, which is supported by two double spherical roller screen bearings. The circle throw action has proven to be very effective in moving coarse material to the top of the bed so that the fines and near mesh particles may pass through the media openings. The T-CLASS Series provides fast and accurate sizing of materials. The T-CLASS Series modular design and the use of standard components result in savings because TYCAN fabricates and assembles machines customized to the application by using standard stock components. This standardization of components also results in readily available spare parts. The T-CLASS simple design combined with its rugged construction results in minimum maintenance and downtime. T-CLASS model 990M on ROSTA elements Hands Free Tube Assembly Typical layout of a T-CLASS with Twin Shaft Assembly PRINCIPAL CHARACTERISTICS: Extremely versatile and maintenance friendly Easy change of Amplitude Adjustable frequency at speeds of 750 to 1050 RPM Dry and humid classification Solid HUCK bolted construction Hands Free tube housing construction for easy bearing exchange Cut sizes from 6 inches to 20 mesh Allows for various classification deck configurations of up to decks Installed at angles of 10 to 25 degrees Width of up to 8 ft Length of up to 24 ft Optional full or partial dust enclosure Optional ball tray for classification of fine and sticky material Optional Twin Shaft Assembly for Heavy Duty Applications 5

6 Horizontal Screening Systems The L-CLASS The TYCAN L-CLASS is designed to operate horizontally and is engineered for various service applications. Itʼs a superior performer in sizing, washing, conveying, and dewatering of materials of intermediate cut size. The L-CLASS is ideal for wet or dry applications and meets demand in existing or planned plants where headroom is limited. The gearless, demountable vibrator emits minimum noise levels, well below minimum noise levels, and can be mounted overhead or under slung of the screen body dependent on space restrictions. The L-CLASS four bearing, stroke-throw vibrating screen is easy to maintain because of its readily replaceable parts and solid HUCK bolted construction. For applications requiring extended bearing life-times the L-Class is also available with our dependable and rugged Exciter Technology. L-CLASS model 6 x16 (2000mm x 5000mm) 1D L-CLASS model 6 x16 (2000mm x 5000mm) 2D PRINCIPAL CHARACTERISTICS: Dual alloy steel counterweight concentric shafts Self-synchronizing drive design Extremely versatile drive head with option of overhead or under slung design Adjustable frequency at speeds of 750 to 1050 RPM Dry and humid classification Solid HUCK bolted construction Cut sizes from 3 inches to 20 mesh Allows for various classification deck configurations of up to 3 decks Installed at angles of 3 to 6 degrees Width of up to 8 ft (2500mm) Length of up to 20 ft (7500mm) Optional full or partial dust enclosure Optional ball tray for classification of fine and sticky material 6

7 Horizontal Screening Systems The XL- CLASS Todayʼs markets have increasingly been demanding higher production rates in form of bigger machines as well as superior machine availability. Traditional shaft driven technology reaches its limitations at a determined width due to the mechanical deflection of the shaft resulting in unacceptable bearing lifetimes. TYCANʼs solution to the marketʼs demands and the technological limitations of the shaft technology is the exciter driven XL-Class. The exciter is a completely incased drive unit consisting of short shafts supported by closely positioned bearings. Mounted on a specially designed over head bridge the exciter technology allows TYCANʼs XL-Class to be built at widths in excess of 8ft addressing the market need for bigger machines. Due to carefully chosen bearing sizes in combination with maintenance friendly lubrication via oil the demand for availability is addressed by bearing lifetimes as high as 50,000 hours (application dependant). Not only does the XL- Class set new standards in its drive principle but also in its body design. Enabling forces of more than 5g (application dependant) the XL-Class is engineered using state of the art Finite Element Analysis technology (FEA). FEA enables structural calculations by simulating the machineʼs dynamic behavior in form of a 3D model. The results of the simulation allow the determination of resulting tensions and natural frequencies to assure a technologically optimized and economically sound design. XL-CLASS 8 x 20 (2400mm x 6000mm) 2D XL-CLASS 8 x 24 (2400mm x 7500mm) 1D dewatering Traditionally developed for the mining industries such as copper and iron ore the XL-Class is also finding its way into construction materials such as sand, crushed stone and aggregates due to its impressive payback and maintenance friendliness. XL-CLASS Exciter Technology PRINCIPAL CHARACTERISTICS: Driven by oil lubricated, easily interchangeable exciter units Bearing lifetime of up to 50,000 (application dependant) Adjustable frequency at speeds of 750 to 1050 RPM Versatility in stroke by weight additions to the exciter counterweight Allows for various classification deck configurations of up to 3 decks Can be installed of 15 degrees Width in excess of 14 ft (4000mm) Length in excess of 36 ft (11000mm) 7

8 Horizontal Screening Systems The XL-CLASS Banana Certain applications call for versatility in changeability of screening surface angles. TYCAN answers this market demand with the XL-Class Custom Slope Deck, designed to provide high yield and efficiency in screening. Larger angles of inclination in the feeding area offer a speed gain in the material flow, which assures a reduced height in the screening layer and allows fine materials to easily pass through the screening media. Subsequent changes in the inclination angles of the media along the screen structure assure a reduction of flow speed allowing the final layer thickness to increase, thus insuring accurate sizing performance at the screenʼs discharge end. The Custom Slope Deck screenʼs mechanical structure is strong and solid and entirely equipped with Huckbolts, providing high operating capacity and low maintenance cost. XL-CLASS Banana-type 8 x 24 (2400mm x 7500mm) PRINCIPAL CHARACTERISTICS: Linear Free Vibrating System with Exciters Strength and Reliability High efficiency in screening Easy to operate and to install Material in non-laminate format Designed specifically for granulometric applications with high concentrations of under-sized materials Drive system: Larger angles allow a speed gain in the material flow The drive system of the Banana vibrating screen consists of exciters which are essentially composed of counterweights attached to a rigid shaft that seats in special bearings. These bearings were developed for vibrating equipment and have a useful life of 50,000 working hours or more (application dependant). 8

9 De-Watering Systems D-CLASS exciter driven Discharged, dewatered product The D-CLASS The TYCAN D-Class was mainly conceived for the iron ore industry in order to minimize the percentage of water residue in the product, enabling a substantial improvement in the handling, transport and piling up of ore. Used for dewatering of various products, the equipment works to allow for better material compacting and consequent water expulsion. Depending on the machine size and application, one of the free linear motion drive assemblies is used. Apart from the characteristics of the free linear motion screen, the dewatering screen has the following features: D-CLASS Unbalanced motor driven PRINCIPAL CHARACTERISTICS: Heavy construction Use of polyurethane screen media or rubber Totally rubber covered for protection against abrasion 9

10 High Speed Screening Systems S-CLASS 4 x 8 (1200mm x 2500mm) The S-CLASS S-CLASS is a versatile high speed circle-throw movement machine designed for medium and fine screening of very difficult wet or dry materials such as sands, gravel, lime, coal, chemicals, fertilizers, gold and metal ores. The S-CLASS is a tough two bearing machine with flexibility to meet demanding and changeable screening conditions. The vibration of the S-CLASS is developed by a counterbalanced shaft assembly which is supported by two double spherical roller screen bearings mounted in ductile iron bearing housings at each end of the vibrator assembly. The vibrator is located over top of the vibrating screen body and is demountable for service. The circle-throw motion produced by the vibrating head is transferred into a forward inclined elliptical action on the screen surface at the feed end and into a backward inclined ellipse at the discharge end. This special design creates high transport velocities at the feed end and lower ones at the discharge end. This causes a quick and equal distribution of the material on the first third of the screen deck and a sharper screening at the last third. PRINCIPAL CHARACTERISTICS: Alloy steel counterweighted shaft ground with precision tolerances Demountable vibrator head assembly Self-contained oil bath lubrication Adjustable frequency at speeds of 820 RPM to 3200 RPM Dry and humid classification Solid HUCK bolted construction with CORTEN side plates Cut sizes from 3 4 inches to 100 mesh Demountable vibrator head assembly Allows for various classification deck configurations of up to 2 decks Installed at angles of 5 to 30 degrees depending on application Width of up to 5 ft (1500mm) Length of up to 12 ft (3500mm) Optional full or partial closure for dust collection Optional ball tray for classification of fine and sticky material 10

11 Fine Screening Systems The H-CLASS / The FINELINE TYCAN has two systems for fine screening, the TYCAN H-Class and the TYCAN Fineline. The designs were conceived in order to obtain high efficiency, versatility and simplicity of operation and maintenance. The operation principle utilizes high frequency vibrating motors, which directly excite the screening media without transmitting vibration into the screen body. The range of products that may be classified with this equipment is very wide. The excellent results achieved during operation at industrial level for the classification of products speak for themselves. H-CLASS V85 4 x15 (1200mm x 4500mm) FINELINE System Feeding PRINCIPAL CHARACTERISTICS: Simple and modular design Higher screening capacity (t/m 2 /h) when compared with traditional screens Higher classification efficiencies Dry classification Drive by means of vibrating motors Adjustable frequency, amplitude and inclination Static screen box, avoiding the transmission of vibration into the structure Allows for quick and easy change of the screening media Low energy consumption Reduced maintenance Enclosed for dust collection Cuts between 0.1 and 5 mm Allows for configurations of 1 or 2 classification decks Modules up to 6 ft wide x 5 ft long Screening Media Overflow Underflow Adjustable Inclination Vibrating Motor 11

12 Engineered Media TYCAN strives to be an application oriented solutions provider by offering a wide media product line, ranging from the standard wire cloth decks to performance engineered screening systems such polyurethane panels, self-cleaning wire screens with urethane strips and perforated plate. The ISO 9002 laboratory equipment and sieves, with which Washington S. Tyler revolutionized the analyzing process of bulk materials since the turn of the 20th century, remain a very important part of the product family. The new generation of product analysis has been introduced with Tylerʼs photo analytical technology. Diversifying into new markets, the media division also supplies numerous woven wire products into the chemical, pharmaceutical and even architectural industries. Cobra Vibe self-cleaning screens Engineered media solutions Polyurethane media solutions Computerized Particle Analysis Woven Wire Cloth Screens Full Screening Media product line Finger Deck solutions 12

13 Vibrating Feeding Systems: V-Feeders Tubular vibrating feeder Typical installation of a vibrating feeder TYCAN vibrating feeders are used in many and various applications, one of which is the withdrawal of product from silos and feeding and distribution of materials to the vibrating screens. The drive is designed to use two vibrating motors with opposite rotation directions. Depending on the necessity, the feeders may be configured openly or enclosed to ensure dust collection. Model UF Model UF R Model UF A Model UF with support frame Product withdrawal from the silo feeding of the screen Inclinated gate Circular gate Flat Gate Bars Gate 13

14 Hydro - Clean Before Afterwards Often customers not only require screened product but cleanly screened products, TYCAN has developed a technology capable of cleaning material mixtures with particle sizes ranging from mm, with the use of high pressured water: The TYCAN Hydro Clean. The result of this technological quantum leap is a high pressure cleaning system for production rates from 50 to 400 tons of output material per hour. Designed similar to a household washing machine the contaminated material is fed into an actual washing chamber by a hopper. Inside the machine the material builds a column standing on a conveyor belt, the speed of which controls the throughput of the material and the washing cycle. To protect the chamber, its inside is lined with standard polyurethane screening panels allowing dirty water to escape and be returned to a settling pond. The constantly recycled water is fed to jet valves, which rotate at the top of the washing chamber. As a result the water is injected at rates from 800 to 2000 PSI and intensely interacts with the contaminated product by blowing onto the particles and penetrating porous areas, which friction based washing technology could never reach. This means the Hydro Clean is capable of offering never before seen cleaning degrees. Products thought to be impossible to clean can now be sold at premium prices. Typical installation of a Hydro-Clean ADVANTAGES: Highest cleaning results possible Lowest water consumption available No tool wearing water jet The water jet reaches directly the material to be washed The drum is coated with PUR-standard screens Optimum material adaptation 1- Input material; 2- Washing rotor; 3- High pressure nozzle; 4- Washing chamber; 5- Material output conveyor; 6- Contaminated water. 14

15 Pelletizing Systems Installation of a Pelletizing Disk line Model GR7500 for iron ore TYCAN also offers pelletizing disks, which are frequently used in the pelleting of materials such as iron ore. The operation principle of the equipment consists in the continual feeding of powdered material, processing it into granules of uniform size. This process is obtained by means of regular rotation of the inclined plate, together with the repeated rolling movement of the product and the simultaneous addition of liquid. PRINCIPAL CHARACTERISTICS: Heavy duty design Vibration free design Dimensions up to 7,5 m of diameter Allows for precise rotation Device for cleaning of the machine bottom and borders Regulated Inclination Centralized Lubrication 15

16 Extraordinary Solutions King-Sized Screens For customers that demand the answer to extraordinary problems, TYCAN has the solution. Those projects are designed on the highest technical criterias and the most modern technology. HBL Latinoamericana team The new tools used to design and calculate such mammoth-sized machines, range from 3D-design over Finite Element Analysis (FEA) to specially designed test measurements of vibration modes. Driven by multiple exciters and decades of experience in manufacturing vibrating screens, TYCAN can provide these type of large-sized machines with width of up to 13 ft and length of up to 36 ft. BASIC DATA: XL-Class Vibrating Screen 4,000 x 11,000 mm Width: 13 ft (4,000 mm) Length: 36 ft (11,000 mm) Screen total weight: 110 tons Capacity: 10,000 t/h Total number of coil springs:

17 Extraordinary Solutions Engineered to Application L-CLASS X x 24 (2400mm x 7500mm) 3D In addition to decades of experience in researching and developing vibrating screens, TYCAN counts on: 3D Design; Structural calculation based on Finite Element Analysis (FEA); Calculation testing through tension measurement with strain gages; Measurement of vibrating modes; Drive by high performance exciters. To engineer solutions to customer requirements and specification. T-CLASS CD1102 Grizzly UM L-CLASS 3 x 14 (1000mm x 4000mm) T-CLASS model ICS - Integrated cooling system for the refrigeration of bearings in hot applications UM L-CLASS 4 x 10 (1200mm x 3000mm) 17

18 Services ESS Engineered Screening Study Our aim is not only to satisfy our customers with our machinery, but to provide complete solutions. Therefore, the services of TYCANʼs engineering department are not limited to machines but allow the following services: Engineered Screening Studies Running different R&D projects and design studies on TYCAN machines our engineers provide a complete process analysis in the form of an Engineered Screening Study (ESS). Utilizing our own programmed software and digitized tools, TYCAN Engineering can provide complete screening and crushing studies for existing or future projects ranging from a one-deck system to high-capacity processing plants. The basic data for such Engineered Screening Studies (ESS) are provided by the customer on-site during the visit of our TYCAN engineer. The data is used to build a computerized model of the customerʼs existing or new plant and operation. Depending on the customerʼs improvement targets, the impact of changes to plant settings can be tested by the model in a fast and efficient manner, revealing the correct and necessary adjustments in terms of process optimization and process design. To visualize the different scenarios, computerized flow sheets are developed which demonstrate the related efficiencies and/or usage of the crushing and screening equipment under the different settings. Finally, the customer receives a precise and accurate report documenting the findings, the results, the calculations, and most importantly the recommendations and proposals for the plant layout. These recommendations are backed by our experience and are evaluated and proven where applicable in collaboration with the customerʼs structural engineers. All recommendations to design changes on existing plant structural work show the best accommodation of new or moved equipment and enable the best flow of material under existing circumstances. Fitting of a new machine into an existing structure 18

19 Services Vibration Analysis Self developed and Custom programmed for vibrating screens, TY- CANʼs Vibration Analysis Service (VA) allows for easy hook-up of a lap-top computer to your vibrating screen on site by TYCAN s trained technicians. Based on the data the performance of vibrating screens can be evaluated in terms of proper speed and stroke. Machine and screening media are synchronized by automatic improvement recommendations. The determination of critical and developing faults such as bearing failures, spring problems, loose machine components or other are also possible. The measuring system features up to 8 accelerometer channels allowing a full scale screen performance analysis. The information allows for on-screen display of orbit plots, peak-to-peak and average accelerations and displacements as well as RPM computing and FFT analysis. The results of the tests are put into a valuable and easy to understand customer report. This document not only outlines the analyzed data, but also makes recommendations on how to improve screen performance based on different settings or new parts. Rebuild Programs Not only does TYCAN build screening machines to last, but we can rebuild them to last even longer. Over time and years of constant use even a TYCAN screen can show its age. Now with the TYCAN Rebuild Program you can reduce maintenance costs and even increase your productivity by avoiding costly replacements. Our Rebuild Program can be accomplished on-site to minimize the time your machine is down. Equipment for Vibrating Analysis Preventive maintenance and rebuild programs You can expect prompt on-site evaluations, a detailed itemized report and quotation, scheduling of the rebuilding process and delivery to customer site. A TYCAN Service Representative will be on-site to supervise start-up. Preventative Maintenance Todayʼs market demands for economical products and high production efficiencies make it necessary for our customers to reduce machine downtimes to a minimum. Whether for regular scheduled maintenance routines or in emergency cases the equipment must be ready to produce again as fast as possible. As a screening solutions provider TYCAN has recognized the necessity for a new service. Our Preventative Maintenance Program (PMP) is designed to considerably cut the operation and maintenance costs for our customers vibrating screens and media. Even though emergency situations can never be fully avoided they can be minimized with proper, manufacturer-supported maintenance. But in addition continuous costs for spare parts and service can be reduced significantly with the proper program. The benefits of the general services covered by a preventative TYCAN maintenance program include the combination of our ESS, Vibration Analysis and our Rebuild Program. As a result our customers receive the following advantages: 1. Reduced Service Rates 2. Inspection and Vibration Analysis 3. Sizing Assistance 4. Regular Maintenance & Media Seminars 5. Rebuild Program Management 6. Spare Parts Inventory Management 7. Reduced Spare Part Prices 19

20 The Screening Circle HBL-TYCAN 020 E - Revised 07/05 The machines and plants shown in this leaflet as well as the stated technical parameters are examples of customer-specific technical solutions. Therefor they are subject to modifications. 225 Ontario Street P.O. Box 3006 ST. CATHARINES, Ontario L2R 7B6 Canada Tel: Fax: wstsales@wstyler.on.ca