Optimize screen performance with monitoring and right media

This article was originally published in Dry Bulk in February 2025

Selecting the optimal screening media

Once you have chosen your equipment, the next thing to consider is the selection of the ideal screening media. While there is no universal solution to solve all your potential screening challenges, the right choice can have a positive impact on media lifetime and screening performance. Below are some things to think about when making your selection.

Application-specific media

As a general rule, polyurethane media is more suitable for wet applications whereas rubber media is more suitable for dry applications. Sometimes the specific application will narrow down your options even further. For example, scalping applications require thick and durable media, guiding you firmly towards the selection of thicker rubber materials with smaller open areas.

Balancing wear life versus costs

Is cost or wear life your top priority? Synthetic media gives a long wear life and is easy to switch out when worn. However, wire cloth is preferred in some regions since it carries less upfront costs in most cases the downside being that it also wears out faster, which can lead to a higher overall cost of operation if changeouts are too frequent.

Fire risk

Rubber and polyurethane are quite flammable materials, and fires caused by welding incidents or similar can pose serious threats including health hazards for your operators and lost production for your business. In areas that are susceptible to fire, you can significantly reduce the risks by choosing fire-retardant rubber screening media. With Trellex fire-retardant rubber the entire screen wear protection is fire-retardant including media panels, feedbox lining, spout lining and side lining. Will be launched in 2025.

Modular media

Ideal for mining operations with variable ore types, modular media enables the quick replacement of damaged panels and easy adjustments. However, it may not suit applications demanding maximum throughput due to reduced open areas.

Ease of maintenance

Changing out worn screening media can be time consuming and risky. Modular media (see above) allows you to replace individual panels as needed. You can also reduce the hazards involved in replacing screening media by choosing, for example, Metso’s hammerless attachment system, which not only improves safety, but also reduces change-out time, leading to higher uptime and productivity.

Pegging and blinding

Pegging occurs when particles become wedged in the screen apertures, particularly in near-size material that matches the aperture size, whereas blinding happens when fine or sticky material builds up on the screen surface, blocking apertures and reducing efficiency.

The good news is that your choice of screening media can significantly reduce the risks of pegging and blinding. For example, flexible polyurethane or rubber screening media have smooth surfaces and elastic properties which reduce the chances of particles becoming stuck. And once again, modular media can also be beneficial as it allows the use of different types of panels in sections of the screen where pegging or blinding is most likely.

Ensuring long-term screening performance

Once your operations are up and running, it’s time to consider how to achieve the best screening performance and ensure the longest lifetime for your screening assets. Smooth, efficient operations depend on ongoing maintenance, monitoring, and adherence to recommended operating parameters.

Maintenance

The most obvious aspect to consider is maintenance, parts of which have already been covered above. Scheduled maintenance is critical to ensure the longevity and efficiency of equipment, prevent unexpected breakdowns and maintain safety standards. Shutdowns should be scheduled at regular intervals, depending on the size and type of operation you are running.

Monitoring

Why not take advantage of digital monitoring software to keep track of the health of your equipment and establish optimal maintenance frequency? Remote monitoring tools such as Metso Metrics for screens is one example, enabling real-time monitoring of equipment health, optimising performance, and helping you better plan maintenance activities. Wireless, Bluetooth sensors provide data on strokes, bearing temperatures, and other parameters and, in the case of deviations, alerts are sent to your personnel.