Download - Trommels Polydeck Sam
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Polydeck History
POLYDECK
Pioneer of the ModularSyntheticMedia Industry
Polydeck was the originator of the modular polyurethane screeningconcept, which we developed over forty years ago.
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Polydeck History
Side Tensioned Polyurethane Mat Type Screen
Side tensioned mats were the first attempt to remedy the high wear rateproblems experienced by wire screens. Although it addressed some ofthe wear issues it still had some of the same fundamental problems as
side tensioned wire cloth. Those being
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Polydeck History
Drawbacks Uneven Screening Uneven Wear
Wasted Panels Hardware/ Open Area
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Polydeck History
Growth & Development
Spartanburg, SCPlant Facility
24 Hours a DayOver 150 employees
Exciting Future
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Capabilities
Manufacturing
State of the art equipment and process ensures the industrys highest standards
Quality
Accuracy
Consistency
Polyurethane
and rubberinjectionmoldingmachines
Roboticfabrication& CNCequipment
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Capabilities
Methods of Manufacturing Polydex
Injection Molding
VS
Brand XOpen Cast
Equipment
Manufacturing Time
QualitySurface Features
Accuracy of Openings
Cheap
Hours
QuestionableLimited
Inconsistent
Expensive
3 5 Minutes
ExcellentUnlimited
Excellent
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Capabilities
Research & Development
ToolRoom
Facility
NewInnovative
Products
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Product Line
1st Generation Polydex Heavy Duty Grid Type
Support Frame
12 Pin Fastening Screen Panels
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Product Line
2nd Generation Polydex Longitudinal Channel
Type Support Frame
6 Pin Fastening Screen Panels
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Product Line
3rd Generation Polydex Longitudinal Pipetop
Maxi Type Support Frame
4 Pin Fastening Screen Panels
HIGH OPEN AREA
Up to 35% more open areawithout sacrificing life
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Product Line
Pipetop Maxi Open Area Comparison 1- 1/4 Opening
Provides
- 14 More HolesPer Panel
- 26% More Open Area
- Equal Wear Life
HIGH OPEN AREA
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Product Line
4 th Generation Polydex Pipetop II With Replaceable
Screw in Polyurethane Pipetops
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Product Line
4 th Generation Polydex Pipetop II With Replaceable
Screw in Polyurethane Pipetops
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Product Line
5 th Generation Polydex Pipetop II With Replaceable
Screw in Polyurethane Pipetops
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Product Line
5 th Generation Polydex Pipetop II With Replaceable
Screw in Polyurethane Pipetops
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Product Line
(4) Polydeck trommels, 12D x 14L
(4) 24 x 30.5 Svedala Ball Mills
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Trommels Advantages/Benefits
-Made in Spartanburg, SC USA
-Completely modular design-HIGHEST OPEN AREA in the industry-Injection molded screen panels-In house machining of dies-Cost savings fastening systems-Finite Element Analysis (FEA)
Product Line
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Product Line
Trommel styles
Quadra_ball mill trommel.avi 25' ball mill_top view.avi
Sliding tray trommel_C1.avi
http://localhost/var/www/apps/conversion/tmp/scratch_1/Quadra_ball%20mill%20trommel.avihttp://localhost/var/www/apps/conversion/tmp/borrador.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_1/25'%20ball%20mill_top%20view.avihttp://localhost/var/www/apps/conversion/tmp/borrador.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_1/Sliding%20tray%20trommel_C1.avihttp://localhost/var/www/apps/conversion/tmp/scratch_1/Sliding%20tray%20trommel_C1.avihttp://localhost/var/www/apps/conversion/tmp/scratch_1/25'%20ball%20mill_top%20view.avihttp://localhost/var/www/apps/conversion/tmp/borrador.ppthttp://localhost/var/www/apps/conversion/tmp/scratch_1/Quadra_ball%20mill%20trommel.avi -
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Product Line
Trommel_competitor panels
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Product Line
Trommel_competitor panels
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Product Line
Trommel_competitor panels
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Product Line
Trommel_competitor panels
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Product Line
Trommel styles
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Product Line
Trommel styles
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Product Line
Trommel_competitor panels
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Product Line
Trommel_Laser cut Pipetops (high open area)
Completely Modular system
Documented six sigma, casestudies have proven the Polysnapsystem to have 50% labor savings
over traditional pin style panels.
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Product Line
Trommel_rubber lining
Laser cut rubber
Cold bonded-hand laid REMA rubber
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Product Line
Trommel_modular dams/scrolls
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Product Line
Trommel_modular dams/scrolls
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Product Line
Trommel_FEA analysis
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Product Line
Trommel_FEA analysisFactor of Safety goal of >3
Typical FOS 4 - 5
Load
Component Weight Weight of panels and trommel Sequential Loading
Description: Total weight of all components: Trommel:9359.13 lbs, Panels: 2420 lbs Total: 11779.13 lbs
Slurry Weight Weight of slurry Sequential Loading
Description: See image below for explanation Total: 17381.19 lbs
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Product backgroundHomogeneous material from injection moldings
Polyurethane screen panelsRubber screen panels
Dams, scrolls, divertersNumerous studies have shown wear rate is highly predictable.With this data, operators can easily predict wear rate, and establishblock changeout programs.
Rows Number vs Panel Size
y = 34.516x -0.1001
R2 = 0.9733
y = 32.359x -0.1016
R2 = 0.9927
y = 30.366x -0.0775
R2 = 0.90426.00
27.00
28.00
29.00
30.00
31.00
32.00
2 3 4 5 6 7
Rows Number
P a n e
l S i z e
173.97 Hrs
351.77
665.28
Pow er (665.28)Pow er (351.77)
Pow er (173.97 Hrs)
A p e r t u r e
Row number vs. Aperture
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Product background
Homogeneous material from injection moldingsPolyurethane screen panels
Rubber screen panelsDams, scrolls, diverters
Panels Size Actual vs Predicted
26
27
28
29
30
31
26 27 28 29 30 31
Actual
P r e d i c t e d
Aperture; Actual vs. Predicted
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Field application development
Block changeout background
Panel changeouts occur only as preventative maintenanceMaintenance tasks quantified in blocks or sections
Screen Decks or Trommels typically have 2 4 blocks
Feed block
Intermediate block
Discharge block
Elimination of human error in panel inspections
Decrease in unscheduled maintenanceIncreased efficiency & regularity in maintenance practicesderived from elimination of panel inspections
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Field application development
Block changeout backgroundChange Out
Recommendation Rows
Number
Time A 3
4
2X A 5
3X A
6
7
8
9
10
11
12
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Field application development
Basic sizing theory
Typical sizing requirements fall into two categories
-Classical screening methodology (Measureable % of oversize) vs.-Fluid mechanics methodology (Negligible amounts of oversize)
Basic concepts:- Effective slurry pool, established by dams/scrolls -Open area-Volumetric flow rate calculation: Q = VA-Shock losses due to opening type, and oversize/nearsize
particle interference
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Field application development
Basic sizing theory
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Field application development
Basic sizing theory
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Field application development
Basic sizing theory
Feed end
Intermediate/middle
Discharge end
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Field application development
Basic sizing theory
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Trommel Screens Before After
Polydeck Success
Life=6 Weeks Life=26 Weeks Production bottleneck Extreme wear Excessive downtime Maintenance problems
No production loss for 6 months Maintenance friendly design Equal efficiency
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Application Specific R & D Polydeck Success
A
E C
B
D
(A, B) Various designs of panels were created to evaluate wear life and non-pluggingcharacteristics in the trommel for this application.
(C) Experimenting and refining the Sliding Tray design that acts like a
cartridge in which panels are easily loaded and unloaded without having to removethe spiral and allow panels to be removed while the trommel is still attached to themill if necessary.
(D) Manually experimenting with the slot length to optimize efficiency and wear life ofthe screen.
(E) The first generation test trommel with various designs of panels.
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Trommel Screens
Before After
Polydeck Success
Low open area & Structural Failure High efficiency & extended structural life
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Product Line
Other Polydeck Products Include
Rubber Lining &Urethane Coating
Doubledex System
Support Frames
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