Haver & Boecker Niagara engineers gigantic 8,000-tph, 120-ton vibrating grizzly screen

Haver & Boecker Niagara has custom-engineered what they say is the largest vibrating grizzly screen in the world. Manufactured with Hardox steel perforated plates and grizzly bars for a large Brazilian iron ore operation, the Niagara XL-Class vibrating grizzly screen boasts a capacity of 8,000 tph and a cut size of 200 millimetres. The XL-Class provides the operation with high-capacity screening while maximizing uptime and production. Combined with the grizzly technology, the XL-Class offers the necessary ability to remove large stones, relieving pressure on the primary crusher.  

At 120 tons, the machine's size required a modular approach, so Haver & Boecker Niagara engineered the XL-Class vibrating grizzly screen as two bodies. With this customization, the 1.3-metre particles did not allow for the normal placement of exciters, resulting in adjusting the design to place three exciters beneath each body rather than the standard overhead location. Effectively screening material top sizes of 1.3 metres, the XL-Class grizzly vibrating screen removes oversized materials to relieve the crusher. 

"We recognize that no two operations are the same, which is why Haver & Boecker Niagara takes the time to understand each of our customers and their needs for every new quarry or mine location," said Denilson Moreno, sales manager at Haver & Boecker Niagara. "We have worked with this customer for many years, but as they began production at what is the largest iron ore operation in the world, we realized to truly maximize output, it would require a durable and extremely efficient primary screen. That's what led us to engineer and manufacture this XL-Class, which is now the largest vibrating grizzly screen on the market." 

Haver & Boecker Niagara listened to the operation's challenges and employed its NIAflow plant simulation software to address them. The software analyzed the proposed plans, processes, goals, and material for plant optimization, providing information to the operator and Haver & Boecker Niagara to design and custom engineer the one-deck vibrating grizzly screen.

To help increase uptime, the XL-Class vibrating grizzly screen is with Haver & Boecker Niagara's Pulse condition monitoring (Pulse CM) system. The technology provides the producer with 24/7 access to the health of its vibrating screen. Pulse CM includes up to 20 sensors placed on the bearings and bodies, which continually assess the acceleration of the machine and provide a forecast of the equipment's dynamic condition in intervals of 48 hours, five days, and four weeks. Additionally, the sensors capture real-time information on the monitored equipment and send e-mail alerts to the producer at the first sign of system anomalies. The collected data provides insights into preventive maintenance opportunities.