In 2016, a CPP coal mine site in Australia wanted to handle higher ash seams than the CPP had been designed for. It also was looking to recycle coking coal tailings to produce a thermal product. To achieve this, the mine needed an increased reject screen capacity of up to 1000 tph from their current screen limitation of 650 tph. It routinely operated to approximately 310 tph and would trip approaching 650 tph. A conventional conversion from a 10-year-old brute force 3.6 m x 6.1 m banana screen to a 4.2 m wide screen would have been an adequate but high-cost solution. Instead, the mine decided to install a 3.6 m x 6.1 m Two-Mass as a bolt in replacement. This Two-Mass Screen, rated to maintain magnetite recovery efficiency up to 800 tph with a surge capacity limit of 1000 tph. The Two-Mass Screen was designed by General Kinematics to address the coal mine site’s exact footprint and space envelope of the pre-existing screen.

Troubleshooting the Two-Mass Screen Solution

This Two-Mass Screen solution was not without issues to be addressed. The standard 3×2 row design clashed with the feed box. A shorter 2×3 row design that was previously used on other designs allowed for clearance to the feed box, playing a significant role in the success of this shorter but taller design.

With design issues addressed, other circumstances that cropped up during execution and installation could be dealt with. There had been no substantial installation projects in the coal industry for some time, so naturally, the administrative side of installation involving paperwork did not go as smoothly as it could have. After that was addressed, it was time to test the actual performance of the two mass screen. It initially performed as well as expected. When a teething issue occurred, the OEM took on rapid measures to make sure the customer was happy with the product by keeping all parties informed, providing a complete replacement screen, including all upgrades.

Experience and Adaptability Make All the Difference

The outcome of this project was a screen fully adapted for Australian coal applications, and the mine took the opportunity to ensure robust elimination of any potential issues. Normally, the introduction of new technology creates a list of potential “product improvements,” especially in such a custom setting, but the Two-Mass screen decks and teething issues were all addressed. It was most important to eliminate things like the OEM’s auto-lube system, and feed chute repair needs are also a major consideration for retrofit projects like this.

There is a lesson to be learned through all of this: unexpected difficulties will arise. Being up-to-date on procedures and compliance can lessen the impact of these unexpected difficulties. Adapting technology to tackle these problems can reduce the risk of the same issue cropping up again in the future. Of course, General Kinematics offers cutting-edge industry and machinery knowledge, which is leveraged provide the best outcomes for clients with a variety of needs.

To learn more about how the STM-Screen from General Kinematics is changing the mining industry, or how GK can find a solution for your mining needs, contact one of our six international offices today.

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