Aggregate Production

SCREENING
Screens are use to:

Separate material into

particle size ranges.

To scalp off oversize rock

To screen out fines.

SCREENING
The screening process is based
upon the premise that:

Particle sizes smaller than

the screen cloth opening size will
pass through the screen.

Oversize pieces will be

retained on the screen.

SCREENING
Screens consists of 2, 3, or 4 decks
(layers) of open mesh screen wire
cloth
mounted
one above
the other
in a
rectangular
box.

MESH
The term mesh
refers to the number
of openings per lineal
inch. To count the
number of openings
to an inch, measure
from the center of a
wire to a point one
inch distance.

MESH

The term mesh refers to the

number of openings per lineal in.

CLEAR OPENING
Clear opening
or space is the
distance
between the
inside edges of
two parallel
wires.

CLEAR SQUARE &

MESH OPENING
These screen openings are the
most commonly accepted in the
industry.

FLAT TOP SQUARE

OPENING
Flat top cloth is used as a subscreen
which supports a finer wire cloth.

SCREEN CAPACITY
Capacity is the rate in tons per hr
that 1 sf of screen produces
(passes) of the desired size.
Capacity varies with many factors.

Desired efficiency
Deck
Aggregate-size

SCREEN CAPACITY

Capacity, Fig. 14.18.

Efficiency, Table 14.7
Deck, Table 14.8
Aggregate-size, Table 14.9

SCREEN CAPACITY

The minimum screen

area to provide a
given capacity is
determined by
Equation 14.5, page 436.

SCREENING
EXAMPLE
The product from a 36- by
42-in. jaw crusher is
passed over a 2 and a
1 in. opening vibrating
screen.

CAPACITY OF
CRUSHER

42- by 48-in jaw crusher

Closed setting of 3 in.
Capacity of crusher
Table 14. 3, page 413

190 tph

CAPACITY ADJUSTED
Capacity of crusher 190 tph

Stone unit weight of 110 lb/cf

110lb / cf
Unit Weight Adjustment
1.1
100lb / cf

190 tph 1.1 = 209 tph

SIZE DISTRIBUTION
Fig. 14.5, read down the 3 line to the size.
Percent
passing
is on
the left
side of
the
figure.

QUANTITY
Output of crusher, 209 tph
Size,
%
% in Total Produced
passing range output
tph
in.
Over 2 100-73 27
209
56.4
2- 1
1- 0

73-46
46-0
Total

27
46
100

209
209

56.4
96.2
209

SCREENING EXAMPLE
Output of 42 X 48-in. jaw crusher.
Size,
in.
Over 2_
2_- 1_
1_- 0

Produced
tph
56.4
56.4
96.2
209

SCREENING EXAMPLE
The permissible screen
efficiency is 85%. Determine
the minimum-size screen, in
sq ft, required to handle the
crusher output. The screening
unit is 4 ft wide.

SCREEN WIDTH

STEP 1. QUANTITY

The quantity that will

strike the 2 1/2 in.
screen is the total
output of the crusher:

209 tph

STEP 1. QUANTITY
If the 2 in. screen was 100%
efficient (56.4 + 96.2) 152.6 tph
would pass through to the 1 in.
screen.
Size,
Produced
tph
in.
21/2 - 11/2
56.4
11/2 - 0
96.2
152.6

STEP 1. QUANTITY
But the 2 in. screen
has an 85% efficient,
therefore only 129.7 tph
strike the 1 in. screen.

152 .6 85 % 129 .7 tph

STEP 2. SCREEN
CAPACITY
Screen capacity, Fig. 14.18
2 inch -

4.21.1= 4.6 tph per sf

1 inch -

3.41.1= 3.7 tph per sf

STEP 3. EFFICIENCY

Efficiency factors, Table

14.7
The permissible screen
efficiency is 85%.

Efficiency factor - 1.5

STEP 4. DECK
Deck factors, Table 14.8
2 inch - Deck 1

Deck factor 1.00

1 inch - Deck 2

Deck factor 0.90

STEP 4 AGGREGATE-SIZE
Aggregate-size factors, Table 14.9
Need % of aggregate less than 1/2
the size of the screen opening.
One-half size for 2 1/2 inch screen:

2.5 in. screen opening

1 14 in.
2

STEP 4.
AGGREGATE-SIZE
One-half size for 2 inch
screen is 1 in.
Figure 14.5 percent

passing
1 in., for 3 in. closed
setting:

= 39%

STEP 4.
AGGREGATE-SIZE
Percent passing 1 in.,

39%
Quantity less than 1 in.:
209 tph 0.39 = 81.51 tph

STEP 4.
AGGREGATE-SIZE
Percent of aggregate less
than one-half size for 2 in.
screen. 81.51 tph
0.39%
209 tph
In this case it was obvious, lets
go on to the 1 in. screen.

STEP 4.
AGGREGATE-SIZE
Aggregate size factor for
2 inch screen with 39%
passing 1 in. Table 14.9
0.20

0.80
9 0.98
10

STEP 4.
AGGREGATE-SIZE
One-half size for 1 inch screen:

1.5 in. screen opening

3 4 in.
2
Figure 14.5, percent passing in.,
for 3 in. closed setting:

26%

STEP 4.
AGGREGATE-SIZE
Percent passing in.,

26%

Quantity: 209 tph 0.26 = 54.3

However, this must be adjusted
because of the 85% efficiency of
the 2 in. screen.

STEP 4.
AGGREGATE-SIZE
Adjusted because of 2 in.
screen 85% efficiency, the
one-half size for 1 inch
screen is:
54.3 tph 0.85 = 46.2 tph

STEP 4.
AGGREGATE-SIZE
Percent of aggregate less
than one-half size for 1
in. screen.
46.2 tph
0.35%
129 .7 tph

STEP 4.
AGGREGATE-SIZE
Aggregate size factor for
1 inch screen with 35%
passing in. Table 14.9

0.20
0.80
5 0.90
10

STEP 5. NET SCREEN

SIZE
Formula 14.5, p. 436

2 in. screen
Q = 209 tph
C = 4.6 tph/sf
E = 1.5

D = 1.0
G = 0.98

209 tph
A
30.9 sf
4.6 tph / sf 1.5 1.0 0.98

STEP 5. NET SCREEN

SIZE
Formula 14.5

1 in. screen
Q = 129.7 tph
C = 3.7 tph/sf
E = 1.5

D = 0.90
G = 0.90

129 .7 tph
A
28.9 sf
3.7 tph / sf 1.5 0.90 0.90

STEP 6. GROSS
SCREEN SIZE
Prudent (p. 434) to have
gross capacity 10 - 25%
greater than net capacity.
2 in. screen
30.9 1.1 = 34.0 sf minimum

STEP 6. GROSS
SCREEN SIZE
Gross capacity 10 - 25%
greater than net capacity.
1 in. screen
28.9 1.1 = 31.8 sf minimum

STEP 7. SCREEN SIZE

Screen size must match
screening unit box width.

2 in. screen
34 sf
= 8.5 ft
4 ft width

Therefore, a 4 X 8.5 screen

STEP 7. SCREEN SIZE

Screen size must match
screening unit box width.

1 in. screen
31.8 sf
= 8.0 ft
4 ft width

Therefore, a 4 X 8 screen

SCREENING

How about that stone!