Industry traditional separated screening equipment usually meets a number of limitations, such as long assembly period on the working place, expensive civil construction costs, limited specifications of screening from one unit of equipment, large size due to several equipment units, narrow maintenance area, inconvenient transportation of customized equipment, difficult reusability during upgrading of the production line and complicated initial design.These limitations influence new building production lines and reconstruction projects in mining operations, quarries, aggregates classification plant, and construction waste recycling screening projects.MP modular crushing and screening solution represents a pre-designed and pre-assembled modular design that solves all of the above industry limitations.It will allow significantly reducing installation and commissioning cycles, civil construction costs and auxiliary equipment, and simplifying of initial design of the project.The module is able to operate independently for screening purposes or it may be connected with MP series jaw crusher modules and cone crusher modules for creation of the whole crushing and screening production line.This way, you will get quick realization of your project and reduction of investment return period.MP MS3YK2060 Circular Vibrating Screen Module uses the 3YK2060 three-layer circular vibrating screen as the basic unit.The module contains complete feeding and discharge conveyor systems and standardized supporting frame.The whole system has safe and compliant operation while possessing a number of advantages such as high-efficient screening, simultaneous production of several aggregates specifications, quick lifting and installation, stable durability and maintenance convenience.It is suitable for small, medium and large aggregate processing projects with different production capacity needs.
The equipment contains 3YK2060 three-layer circular vibrating screen.The screening area is 12㎡ and the equipment processing capacity is 80-500tph.The large screening area increases material stratification and screening performance making it appropriate for high-capacity aggregate classification applications.
The standard configuration contains four conveyors for finished products discharge:B1200 main discharge conveyor;Three B650 discharge conveyors.Materials classified by the three-layer screening surfaces are simultaneously transported through different discharge channels for production of several aggregate specifications.
The whole equipment is designed according to fully modular integrated frame concept.All assembly work is conducted inside the factory before delivery.After delivering on the site, the equipment only requires quick lifting, positioning and pipeline connection for starting the production.This will reduce civil construction requirements, time and labor expenses.
In accordance with the well-known technology of industrial screening equipment design, all main vibration and conveying elements are supplied by reliable industrial companies.This equipment operates with low failure rates under the heavy-duty operation and provides high reliability and long life.
The complete machine structure has enough space for removing and replacing wear parts.Specialized maintenance platforms are installed around the main screening and conveying zones.An operator may conduct inspection and replacing operations without using any additional tooling.
Name | Specification | Installed Power (kW) |
Circular Vibrating Screen Main Unit | 3YK2060 | 30 |
Feeding Conveyor (Main Feeding) Belt | Width 1200mm | 15 |
Discharge Conveyor 1 Belt | Width 1200mm | 7.5 |
Discharge Conveyor 2 Belt | Width 650mm | 5.5 |
Discharge Conveyor 3 Belt | Width 650mm | 5.5 |
Discharge Conveyor 4 Belt | Width 650mm | 5.5 |
Electrical Control Cabinet Integrated electrical control system for complete equipment | — | — |
Walkways and Stairs | Full inspection walkways and stairs with protective guardrails | — |
Item | Technical Data |
Total Installed Power | 69kW (total power of all conveyor motors) |
Total Equipment Weight | 9,200kg (without screen mesh components) |
The 30kW motor of circular vibrating screen is the power source of the whole module.
This motor powers exciter for generating constant screening vibration force.The power configuration contains enough margin for 12㎡ three-layer screening surface and heavy-duty operation up to 500tph.This prevents such common issues in low-power screening equipment as lack of vibration force, bad material separation, screen surface clogging and inability to reach required screening accuracy.The front feeding conveyor has 1200mm belt width and 15kW driving motor.Such configuration corresponds fully to maximal feeding load of the equipment.Large conveyor belt width and sufficient power prevent slipping, material clogging or interruption of feeding process because of abrupt changes in material flow rate.This guarantees constant feeding from the crushing process to screening unit and prevents unsteady screening load that influences quality of finished products.The bottom fine material discharge conveyor has 1200mm belt width and 7.5kW driving motor.Materials such as stone powder and fine sand usually have more bulk density and maximal discharge capacity per time.Therefore, larger belt width and more powerful motor provide higher carrying capacity and prevent material overflow and conveyor clogging and shut down.The upper and middle coarse aggregate discharge conveyors have 650mm narrow belts with 5.5kW low-power motors.Because larger aggregate discharge volume is significantly smaller than fine material discharge volume, the narrow belt width and low-power motor configuration correspond precisely to real conveying load.This design meets transportation requirements and reduces equipment purchasing costs and energy consumption.In large scale production, it is very important.
The total installed power of 69kW is a combination of the power rating of vibrating screen and all five conveyor belt motors.It is used as a common reference in the initial project electric design, transformer choice, cables calculation, and power distribution room design.It is not necessary for customers to calculate separately the power of many individual units, thus significantly minimizing work related to communication with engineering design groups and changes in drawings in the early stage of the project development.Meanwhile, the constant value of the total power can be easily applied in calculation of the electricity consumption for production.It helps investors to analyze operation benefits, calculate energy cost per ton of material, and to conduct project profitability analysis.
The total equipment weight is the weight of all permanently mounted units including the weight of equipment frame, vibrating screen, conveyor structures, maintenance walkways, etc.Screen mesh is a consumable unit that is not included in this weight value.This technical parameter gives three practical advantages:First, it gives a base for selection of the transport container and lifting equipment during installation.Standard 25 tons mobile crane is enough for all lifting and installation operations, saving money for crane rent.Second, it gives a basis for the site bearing capacity calculation.Just a standard hard surface or compacted ground is required to place the equipment.Heavy reinforced concrete foundation for equipment is not needed, saving costs of civil construction works and time.Third, it gives a load reference value for the future re-location and production line modifications.It allows the customer to quickly choose the transport equipment and increase equipment reusability.
The integrated electrical control cabinet allows to control all the vibrating screen and conveyors in one cabinet.It allows operation control and provides internal protective function such as overload and material jamming interlock shutdown.This solution eliminates the problems of independent units wiring such as complicated cables laying, risk of electric shock and difficulties in the operation.The full length inspection walkways system with guardrails and stairs provide direct access to all maintenance points, including:The vibration exciter.Conveyors roller.Areas of screen mesh replacement.All inspection and maintenance points are designed in compliance with mining safety operation requirements.No temporary scaffolding is needed.It minimizes the inspection time, reduces the component replacement time and decreases the risks connected with high-altitude work.
Inspection Item | Standard Parameter |
Main Unit Model | 3YK2060 |
Screen Size | 2000×6000mm |
Screening Area | 12㎡ |
Number of Screen Decks | 3 Layers |
Maximal Feed Size | <200mm |
Optional Screen Mesh Opening Range | 2-65mm |
Theoretical Process Capacity | 80-500tph |
Standard Double Amplitude | 7-10mm |
Vibrating Screen Motor Power | 30kW |
Many screening machines of similar price class have shorter screening surface.The shorter material screening time and shorter screening travel distance make it impossible for fine material to go through the screen during discharge.The result is excess of powders and impurities in finished aggregates and decrease in product market value.The MS3YK2060 has 6000mm long screening surface, thus increasing the material screening time.The 2000mm wide screening surface allows to distribute material in the thin layer.Thus the total 12㎡ screening area improves screening performance.The resulting finished aggregates have higher cleanness and quality.At the same time, large screening area gives the wide range of processing capacities from 80 to 500tph.Small temporary aggregate production can operate under low load, and large aggregate production facility can work in high-capacity regime.The equipment has increased versatility and there is no need for changing screening machine depending on the production capacity requirement.
Three independent screening decks allow to make three stage screening operation in one go.The equipment allows to produce simultaneously several aggregate sizes along with bottom-layer fines.There is no need to buy several vibrating screens for serial mounting.Thus it effectively reduces:equipment investment,space requirements on the factory floor,conveyor systems,motor configurations,civil foundation construction costs.The centralized screening design simplifies whole production process.It decreases the repetitions of material transfer between many machines, thus saving material losses during transportation and decreasing dust emission.
This parameter shows the safety operation boundary of the equipment and gives the important reference for matching with upstream crushing equipment.The MS3YK2060 module is designed as screening unit after medium and fine crushing.It is possible to control the discharge particle size from mainstream jaw crushers and cone crushers under 200mm.Thus this parameter is fully compatible with the standard crushing process flow.If oversized material constantly exceeds 200mm, large stones will make high-impact loads on the screen mesh and screen frame.The result may be:screen mesh tearing,permanent deformations of side plates,additional stress on the exciter,accelerated fatigue destruction of damping springs and bearings.This parameter gives the clear requirement to feed material size standard.It allows customers to properly control material size during upstream crushing process and avoid severe equipment damage, shutdowns and additional maintenance costs.
The minimal opening size of 2mm gives possibility to process stone powder and high-quality fine sand.The maximal opening size of 65mm gives possibility to produce large-size aggregates such as road base material and railway ballast.The complete opening range covers the mainstream aggregate sizes that are used in:Road construction.Infrastructure projects.Commercial concrete plants.Railway ballast production.The customers are able to freely configure the three layers screen mesh openings depending on local market demands.One machine allows to produce different finished product mixtures without replacement of screening equipment.
Lower processing capacity of 80tph is perfectly suitable for small village-level quarry aggregate and temporary infrastructure aggregate production facility.Under lower capacity working condition, the machinery works under light loading condition, which causes slow wear of consumable spare parts and lower maintenance cost.Higher processing capacity of 500tph perfectly meets all the demands of standardized large-scale aggregate production base for continuous mass production.The broad range of processing capacity is realized via the optimization of:Screen surface area.Vibration amplitude.Upstream feeding flow rate.Through the coordination and optimization of the above three parameters, one screening module can be adapted to small, medium and large-scale aggregate project.In case of expansion of the production capacity in the future, customer needs to increase upstream feeding flow rate only, but not replace the screening main unit, greatly reducing expansion investment.
Vibration amplitude directly affects the material throwing height, material traveling speed and screening efficiency on screen surface.7mm small amplitude is suitable for material with dry and smooth properties.The lower material throwing height reduces screen mesh wear and extends the screen service life.10mm large amplitude improves the material throwing force.It is suitable for material with high moisture content, high clay content or material with tendency to sticking.The stronger vibration is helpful to break up the material adhesion and reduce the screen hole blocking.It is particularly suitable for wet season operation and washed aggregate screening application.The adjustable amplitude range of 7-10mm realizes compatibility with different operating condition, including:Dry material.Wet material.Clean aggregate.Material with high clay content.One equipment unit can realize the adaptation to different raw materials without changing the vibration components.
Different Screen Mesh Size(Custom screen openings of 2-65mm can be chosen according to customers' demand.)
Anti-Clogging Screen Mesh(Polyurethane / Rubber Screen Mesh)
The equipment adopts the three-layer screening structure with the large 12㎡ screening area.Maximum processing capacity reaches 500tph.Under the same installation area, the screening accuracy and production capacity surpasses that of traditional separated screening machine.
Standard equipment configures four discharge conveyors to realize multiple aggregate specifications production simultaneously.It saves additional investment of installing multiple screening machines in series.
The pre-assembled modular unit can be transported by standard container.It reduces transportation cost.After reaching the working site, the equipment only needs lifting and connection to start operation.It greatly shortens the project construction period and accelerates capital recovery.
The standardized modular interfaces allow the equipment to freely combine with other MP series crushing module.Customer can freely configure the open-circuit and closed-circuit crushing and screening production line according to the requirement.Future expansion or modification does not need large change of civil foundation.
The modular frame design provides enough installation space, checking space and component replacement space.Screen mesh and conveyor roller spare parts can be replaced without space limitation.The integrated maintenance platform reduces the daily maintenance time and labor cost.
Q1: With the total installed power of 69kW, can each conveyor motor be started and stopped independently?
A:Yes.The equipment is equipped with integrated electrical control cabinet which can achieve two operation mode:Independent start/stop control of the screening unit and each conveyor belt.Complete integration and interlock control of the complete equipment.According to the on-site feeding condition and finished product discharging requirement, operator can independently start or stop any conveyor belt.The system is equipped with automatic protection logic when the material blockage and overload condition occurs.When the material accumulation or equipment overload condition occurs, the system automatically stops the power operation to prevent conveyor belt tearing and vibrating screen overload damage.
Q2: The equipment specifies the maximum feeding size of <200mm. What irreversible damage may happen when the material above 200mm is fed continuously?
A:The oversized rock material will continuously create the high-impact load on the screen mesh and screen frame.It will quickly cause:Screen mesh tearing.Permanent deformation of the screen frame side plate.At the same time, the impact load will greatly accelerate the fatigue wear of:Exciter bearing.Damping spring.Vibration system component.It reduces the service life of the vibrating motor and may lead to abnormal noise, frequent shutdown and maintenance.Continuous operation with oversized feed material will greatly shorten the designed service life of the complete equipment and increase replacement cost and production loss.
Q3: The standard four discharge conveyors equip with B1200 and B650 belt width. Which material layer do they correspond to, and what is the engineering purpose of the differentiated design?
A:One B1200 wide conveyor receives the bottom-layer fine sand and stone powder materials.Three B650 narrow conveyor corresponds to the upper and middle layer screening, transporting coarse aggregates and oversized materials.The bottom-layer fine material has bigger output volume and greater bulk density.The wide belt improves conveying capacity and prevents material overflow.The upper and middle layer produces smaller output of bigger size aggregates.Narrow belt reduces the equipment purchase cost and operating energy consumption while realizing precise match between conveyor configuration and material load.
Q4: Compare to conventional metal screen mesh, what production conditions are the polyurethane and rubber anti-clogging screen meshes suitable for?
A:The polyurethane and rubber screen meshes have elastic cushioning properties.It is unlikely to accumulate sticky materials during impact.It is suitable for:Material with high clay content.High moisture material.Washed aggregate.Outdoor screening in rainy season.It greatly reduces cleaning frequency caused by screen clogging.The metal screen mesh has higher structural strength and impact resistance.It is more suitable for:Dry hard rock material.Large size high impact aggregate.Dry screening operation with strong impact condition.It has better wear resistance and impact resistance.
Q5: Is there any special reinforced concrete foundation for this modular screening machine? Is it possible to use it directly on the flat working surface?
A:There is no need to prepare any special reinforced concrete foundation.The entire machine uses one integral load-bearing frame with built-in stable supporting structures.The equipment needs a leveled, compacted, and hardened site surface before lifting and installing.There is no need to build special heavy-duty equipment foundations.Customers only need to prepare enough space for the finished products conveying and material transferring.This greatly saves construction time and cost investment.Especially suitable for:Temporary aggregate processing projects.Projects that need frequent site transfer.Mobile crushing and screening projects with different work sites.
Q6: This equipment has a broad processing capacity range of 80-500tph. Which parameters are used to realize flexible production capacity regulation?
A:There are three ways to control the processing capacity:Firstly, customers can change the screen mesh holes with different hole sizes of 2-65mm.Big screen hole sizes will enable the materials to penetrate fast and increase the processing capacity.Secondly, operators can regulate the vibrating amplitude of 7-10mm double amplitude.The increase in the vibration amplitude will improve the material moving speed on the screen surface and raise the quantity of materials processed per minute.Thirdly, the feeding rate from the upstream feeding conveyor can be regulated.With the combination regulation of screen hole sizes, vibration amplitude, and feeding quantity, the equipment will meet various production capacity requirements from 80tph to 500tph.
Q7: In what way can the MS3YK2060 module combine with other MP crushing modules to form a full production line?
A:The connecting elevations and conveyor interfaces of all MP series modules are unified with standardized designs.The input end can be connected with MP jaw crushing modules for supplying the primary crushed materials.The output conveying devices can be connected with MP cone crusher modules to make the closed circuit crushing and screening processes.Or the module can also work independently with finished product storage devices to make the open circuit screening production line.According to different raw material conditions and requirements of finished products, customers can arbitrarily combine process configurations.In case of production capacity expansion in the future, additional modules can be installed without changing the original foundation structure.
Wherever your worksite is located, whatever your equipment specifications require, and no matter how severe the operating conditions — MP Crusher delivers the equipment, the solution, and the performance you need. Our equipment is already at work in more than 20 countries around the world.
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