In high-output mining operations, even small inefficiencies in screening can lead to costly downtime and lost productivity. For decades, iron ore production relied on woven wire screen media due to its availability and cost-effectiveness. However, many mines have found that abrasive material breaks down woven wire screen media quickly, leading to frequent maintenance and increased downtime. This issue caused mines to start looking for an alternative solution, which brought it to the attention of screen media manufacturers.

MAJOR started looking into how to expand the longevity of their screen media while holding up against corrosive environments and came up with options for their high-vibration screen media to expand its lifespan to meet these facilities’ expectations. As a result, MAJOR’s FLEX-MAT comes in multiple configurations to ensure mining operations get the right screen media for their process.

Common Issues in Iron Ore Processing

Woven wire screen media is a common choice for processing facilities everywhere. However, that doesn’t always mean it’s correct for every application. One main issue facilities see is that woven wire screen media features knuckles where the wires cross one another. When material hits the screen panel, this raised point causes the wire to break down faster, meaning screen media needs to be changed out more often and downtime increases.

Additionally, woven wire only comes in specific opening sizes. Typically, iron ore facilities would need to choose between 3/16 of an inch and 1/4 of an inch. If the 3/16 is too small, the only option is to go up to 1/4 inch, but that will allow more undersized material to pass through. This reduces the efficiency of the screening process and often requires additional screening passes. The limited size range means operations may not be able to get the right opening in their woven wire screen media.

Lastly, the abrasive nature of iron ore accelerates the breakdown of the screen media, especially in facilities that feature polyurethane on the screen deck. Corrosive environments break down polyurethane faster than it breaks down the wire, cutting down on the lifespan of the screen media overall.

Advantages of FLEX-MAT

FLEX-MAT high-vibration screen media offers a smarter solution for iron ore operations facing limitations with traditional woven wire. Its independently vibrating wires don’t overlap, eliminating knuckling and ensuring consistent performance. The openings on FLEX-MAT are available in smaller intervals as well, allowing operations to dial in the exact spec they need without having to compromise.

One of the key advantages of FLEX-MAT is its increased wear life. Our proprietary OPTIMUMWIRE^® is engineered in-house using a consistent high-quality metal blend. More importantly, for especially abrasive environments, we offer OPTIMUMWIRE PLUS which can withstand harsh screening conditions longer due to improved hardness.

Our polyurethane is similar, in that we create and mold all polyurethane strips in-house. The polyurethane strips hold the high-vibration wires in place while they vibrate independently. Our advanced polyurethane strips extend the lifespan and overall efficiency of the screen media in abrasive applications to match the lifespan of the wire. The new compound is designed to be more chemically stable and offers superior performance in corrosive areas.

Customer Success

While processing ilmenite, one of our customers found themselves in the situation where neither woven wire nor synthetic screen media could perform to their specifications. Woven wire screens caused excessive blinding while the synthetic screen media couldn’t support the precise 6/25-inch opening they needed.

FLEX-MAT was the only screen media solution that met both requirements of eliminating blinding and achieving the exact opening size needs of their facility. By switching to our high-vibration screen media, they boosted productivity by 30% and extended wear life, allowing them to run continuously until the next scheduled shutdown without unplanned screen changeouts.

Working with an Expert

While woven wire screen media works well for some materials, iron ore demands a more tailored solution. To maximize efficiency and wear life, it’s essential to consult with a screen media expert like MAJOR. Ready to optimize your screening process? Contact us today to learn more about the benefits of FLEX-MAT for iron ore.