Polyurethane screening surfaces have been in use for many years and have proven to be generally economical due to the long wear life and low maintenance requirements.
The extended life is attributed to the SUPERIOR CUT, TEAR AND ABRASION RESISTANCE of polyurethane. The wear life is enhanced by the polymers flexibility, which returns some of the impact energy imparted by the vibrating media.
Noise pollution typical of wire screens and perforated plate is greatly reduced with the introduction of polyurethane screening surfaces.
Correctly applied Polyurethane screens can reduce or even eliminate plugging, pegging and blinding problems due to the tapered openings and resiliency of the material.
Corrosion and rust out are eliminated as Polyurethane is impervious to most elements found in any screening plant.
Aperture shapes are almost unlimited. While wire cloth is typically limited to squares and rectangles, polyurethane screen apertures can be molded to any shape which best serves the particular application.
There are two basic Polyurethane screen types
The polyurethane tension mat is a single piece screen section utilized to replace wire or perforated plate screen panels fitted with a hooked edge to facilitate clamping onto the vibrating deck support structure.
A tension mat is molded in large sections, typically in the same width and length as the metallic system being replaced.
The mat is reinforced with internal cables, rods or bars for strengthening and to provide a means for applying tension.
Installation of a tension mat is very similar to the procedure for installing a woven wire or perforated plate screen section.
Advantages of Tension Mats
Virtually no deck modifications are required with a tension mat as it installs over the existing crown bar deck allowing quick changeover to a new mat or a metallic screen panel.
Disadvantages of Tension Mats
A tension mat is "one large piece". Screens do not wear evenly. Once the high wear areas have worn through the ENTIRE MAT must be replaced. Replacing a mat which is worn or damaged in small areas is a very expensive proposition....as large areas of the mat which still offer useable life must be discarded.
The tension mat is custom manufactured to your specifications, typically requiring long lead times. Once manufactured, changes in the openings necessitated by the application are out of the question due to the nature of the one piece screen.
Tension Mats are quite heavy and extremely difficult to handle.
The Modular System is comprised of a multiple of screening segments installed on a special support frame that accepts locking attachments to hold the modular screening segments.
Several manufacturers offer a modular system in square and rectangular configurations.
Many existing rectangular and square systems are interchangeable with a broad range of locking systems.
Rectangular systems although not typically adaptable to one another, tend to provide more useable open area.
Advantages of Modular Systems
With this type of system individual segments may be relocated on the screen surface as required to equalize wear across the entire screen.
Individual segments may be easily replaced when required due to wear or damage.
Unlike the Tension Mat, a modular system can be conveniently field modified to accommodate a multiple of different specifications on one screening surface.
Individual screening modules are produced more economically than Tension Mats. Reputable manufacturers usually maintain sizable inventories, allowing prompt delivery.
Modular systems are interchangeable providing usefulness of the individual modules throughout the screening plant on any deck fitted with a similar modular frame.
Impact modules, Dam and flow divider modules are easily installed or relocated according to the particular application.
Disadvantages of Modular Systems
Modular systems require the installation of a special support frame. The installation requires drastic modifications to the standard crowned support frame.
Deck modifications necessitated when installing the modular support frame typically void any remaining warranty on the vibrating deck.
One the deck has been altered you CANNOT revert back to wire cloth or perforated plate without costly deck changes or expensive fitments which are labor intensive in installation.
Modular support frames are typically quite HEAVY. This can add hundreds of pounds to the deck weight, decreasing deck life and screen amplitude.
Most modular support frames are subject to wear and may require frequent and expensive replacement.
Although individual modules can typically be replaced in minutes, a complete change out can require several hours of intensive labor. Modular systems are NOT SUITABLE where specification changes are frequent.
The NEW DIRECTION IN SCREEN DECK MODULAR REPLACEMENT
Nepean Quick Swap, Modular tensionable Systems, Uses a modular approach, quick change screening modules, supported by a high strength light weight TENSIONABLE/MODULAR support frame.
Nepean Quick Swap, Modular tensionable Systems does not require vibrating deck modifications.
The Nepean Quick Swap, Modular tensionable Systems support frame is lightweight and can easily be installed and tensioned, just like a woven wire screen, in minutes.
The Nepean Quick Swap, Modular tensionable Systems support frame is PROTECTED by the systems modules, providing extremely long life and further reducing noise levels.
The complete system can be removed and replaced with another system in minutes.
Changing out the complete system is the same procedure as used for cross tensioned punched rubber screen decks, loosen the tension bolts, remove the clamp rail and lift off the system.
Nepean Modular panels provide SUPERIOR useable open area.
Individual modules can be changed out in SECONDS, there are no loose parts and the locking system is integral to the modules.
The Nepean system can also be configured for permanent FLAT DECK installation. The permanent installation frame accepts the same modules as the Tensionable/Modular frame.
Modules are molded of superior TOP QUALITY open cast polyurethane.
|Modular Screening Systems
Nepean Rubber and Plastics supplies replacement panels for most modular screening systems.
Our replacement panel offer our customers equal or greater wear-life, reduced blinding and much faster delivery, and all at lower cost.
Superior polyurethane composition and abrasion-resistant compounds are used by Nepean to produce all of our replacement panels.
|Tensioned Polyurethane Screening Panels
Many tensioned panels are readily available to increase wear-life and improve screening efficiency in circumstances where material specifications frequently change. The ease of installation and the extended wear-life easily justify this change to polyurethane in many severe and abrasive screening situations.
Heavy-duty impact panels can be supplied for the feed area, while greater production polyurethane-tensioned panels can be used on the discharge positions where screening efficiency is the primary concern. The combination of polyurethane impact panels, high-efficiency polyurethane tensioned panels and abrasion-resistant woven wire cloth distinguishes Hoyt as a screening consultant of screen media.