Separation performance of double deck banana screens – Part 2: Quantitative predictions

Abstract

Banana screens are often used for high capacity separation of iron ore, coal and aggregates into different size fractions. They consist of one or more curved decks that are fitted with screen panels with arrays of square or rectangular holes. The screen structure is vibrated while a dense stream of particles flows over it and is separated according to size. The material discharging from the top of the deck is the oversize and may become a coarse product or be crushed and recycled to the screen feed. The material falling through the deck can be further separated by additional decks below. Each lower deck returns a product stream and the material passing out through the bottom deck is the undersize. In this paper, Discrete Element Method (DEM) is used to explore the separation performance of a full industrial scale double deck banana screen for a peak acceleration of 5 g. The separation efficiency of each deck is analysed and the individual contributions of each screen panel are assessed using outputs from the model. Residence time distributions for particles on each deck provide insight into both the transport characteristics along the deck and the separation performance through each deck. The top and bottom decks have very different flow behaviour with very different bed structure and motion. The stresses applied by the flowing particles to the screen cloths and the impact and abrasive wear on the screen surfaces are evaluated. Finally, the energy absorbed by particles provides insight into the extent of particle degradation produced by transiting the screen.