Derrick® Corporation has once again redefined high capacity, high efficiency, fine particle wet screening with the introduction of the SuperStack®. With 8 decks operating in parallel and innovative Front-to-Back (FTB) tensioning system, the SuperStack has a demonstrated capacity up to 3 times that of the best fine screens currently available.
All of this added capacity comes with only a slight increase in the space required per machine, significantly reducing the total capital and installation cost as well as OPEX for any screening installation. The SuperStack is built to last and backed by a worldwide support team available 24/7.
Solutions to your most challenging fine sizing problems:
- Improve efficiency and capacity in closed grinding circuits
- Improve final concentrate grade and recovery
- Improve size classification and product quality, e.g. industrial minerals, heavy minerals, pellets
- Reduce impurities, e.g. silica, alumina, in fine iron application
- Pumping and pipeline protection by removing coarse and abrasive particles
- Fine coal de-sliming to reduce ash content
- High-capacity trash removal
SuperStack 8-Deck Design
Dual vibratory motors are positioned directly over the upper screen frame to deliver linear vibratory motion to all eight screen decks. The motors have an internal oil lubrication system that eliminates the need for a separate lubrication system, while providing long-term maintenance-free operation and low sound production.
Dual oversize launders (one per side) and a single undersize launder eliminate the need for a large hopper, minimising height requirements. Each feeder has an easily removed front cover to facilitate maintenance and debris removal.
Custom designed inlet pipe configurations are available from Derrick if needed to meet equipment layout requirements. The Flo-Divider™, which equalizes flow from the feed source to each deck, is available in a number of discharge outlet configurations from 2-way to 16-way. An optional repulp spray system introduces free water into replaceable rubber wash troughs to help undersize material pass through screen openings.
“The SuperStack is a highly efficient means of achieving major production increases within a comparatively small footprint,” says Todd Burchett, Vice President – Mining and Industrial Division. He adds, “Consequently, we expect the SuperStack to fill the need for higher productivity in facilities where space is limited.” Mitch Derrick – CEO explains “This innovative solution offers over twice the capacity of traditional units in a similar footprint, significantly reducing both the upfront installation costs and ongoing operating and maintenance costs.”
Front-to-Back (FTB) Screen Tensioning – Increase Capacity and Reduce Screen Panel Change Time
Derrick proudly introduces the latest innovation in fine screening technology, Front-to-Back (FTB) screen tensioning. Customers using the Derrick SuperStack report significant capacity increases over their previous screening equipment. These increases are attributed to the rotation of each screen section’s crown 90 degrees, parallel to material flow.
This change in crown direction assures an even distribution of material across the entire width of the screen and engages 100 percent of the screening surface. It also minimises migration of oversize particles to the outside edges of the screening deck. This even distribution of material leads to increased panel life by reducing panel wear caused by oversize solids conveying in concentrated areas.
Customers report the ability to change screen panels extremely fast–typically less than one (1) minute per screen panel. Using a single long-handled wrench, the operator turns a rotating tension bar assembly to draw each screen panel into tension. A single locking nut is then tightened to secure the applied tension.
A full range of Derrick Polyweb® urethane screen panels are available for the SuperStack, from 53 to 1000 μm with slotted openings.
Case Study:
The high screening capacity of the SuperStack machine allows frac sand producers to change the way their current wet plant operates, or even eliminate the need for costly dry screening.
Producing API in-spec frac sand from your wash plant is now easier than ever before.
The expanded capacity per screen means:
–– Reduced size of supporting structures
–– Less flow dividers
–– Less pumps are needed to operate and maintain
–– Reduced capital costs and operating costs
Expanding on the success of the 5-Deck Stack Sizer®, Derrick Corporation developed the expanded 8-Deck model called the SuperStack. Capable of processing 2-3 times more frac sand as the original 5-Deck Stack Sizer, while maintaining almost the same footprint. Patented design improvements included increasing the number of decks, expanding the width of the decks and incorporation of the new FTB screen tensioning system.
A frac sand producer in the central US, American Silica, incorporated SuperStack machines into their wet process that successfully made in-spec 30/50, 40/70 and 100 Mesh frac sand with 5-Deck Stack Sizers. SuperStack machines replaced multiple 5-Deck machines making 30 mesh, 50 mesh and 70 mesh separations. Plant capacity increased even as the number of operating machines decreased. The SuperStack units were installed in the former locations of 5-Deck Stack Sizers with minimal installation time.
Derrick Polyweb urethane high open area, non-blinding screen surfaces are the key component for the SuperStack machines. For the frac sand application, a 12 month screen panel life was typical. Screen panel changes were few but much faster than screen panel changes on the 5-Deck Stack Sizer.
Dan Cook of American Silica describes their experience with the Superstack, “We’ve seen a vast improvement in quality and efficiency.” Cook is especially pleased with the ease of changing the SuperStack screen panels.
He says, “The front-to-back tensioning makes screen changes faster than the 5-deck.” Noting the productivity improvement, Cook comments that, “Plant capacity has increased by about 35 percent. We’ve gone from 700 tons per shift to 950 tons per shift! And we believe it can handle more than what it’s rated for. We’re really pleased with the 8-deck!” he concludes.
