trommels polydeck sam

8/13/2019 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



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Product Line

3rd Generation Polydex Longitudinal Pipetop

Maxi Type Support Frame


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




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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 styles


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Product Line

Trommel styles


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Product Line



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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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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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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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Basic sizing theory


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Basic sizing theory


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Basic sizing theory

Feed end

Intermediate/middle

Discharge end


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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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trommels polydeck sam

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