Method and apparatus for screening

Abstract

Methods and apparatus for screening are provided. Embodiments include a screen basket apparatus for screening material, comprising: a grid frame (1510) having a plurality of openings (1513) arranged in a lattice; and a plurality of screening filter element assemblies (1610a, 1610b, 1610c) fixed on the grid frame (1510) so as to cover each opening (1513) of the grid frame (1510). The screening cartridge assembly (1610a, 1610b, 1610c) includes a housing (1630a) and a screen assembly (1640a, 1640b) fitted into the housing (1630a), and may be secured to a set of cross members (1512) of the grille frame (1510). The housing (1630a) may be an injection molded thermoplastic polyurethane or a thermoset polymer. The screen elements together form a generally continuous screening surface across an exterior of the grille frame (1510).

Description

[0001] This application is a divisional application of the patent application with application number 201880037894.8.

[0002] Cross - reference to related applications

[0003] This application claims priority to U.S. Patent Application No. 62 / 515,964, filed on June 6, 2017, and U.S. Patent Application No. 62 / 615,302, filed on January 9, 2018. The contents of both are incorporated herein by reference, and the priority of both is claimed. Brief description of the drawings

[0004] Aspects and features of the present disclosure are described herein with reference to the drawings. Throughout the text, like numerals represent like but not necessarily identical or the same elements.

[0005] Figure 1 A side view of a screen basket according to an exemplary embodiment of the present disclosure is shown.

[0006] Figure 2 A top view of a screen basket according to an exemplary embodiment of the present disclosure is shown.

[0007] Figure 3 A top perspective view of a screen basket according to an exemplary embodiment of the present disclosure is shown.

[0008] Figure 4 A top view of a polyurethane screen used with a basket cage according to an exemplary embodiment of the present disclosure is shown.

[0009] Figure 5 Shown Figure 4 The bottom view of the polyurethane screen.

[0010] Figure 6 A side view of a polyurethane screen used with a basket cage according to an exemplary embodiment of the present disclosure is shown.

[0011] Figure 7 Is a partial top view showing the attachment of a screen member to a basket frame according to an exemplary embodiment of the present disclosure.

[0012] Figure 8 Shows Figure 4 A portion of the polyurethane screen shown.

[0013] Figure 8A Shows Figure 8 An enlarged view of a portion of the polyurethane screen shown.

[0014] Figure 9 A partial side - view cross - sectional view of a polyurethane screen according to an exemplary embodiment of the present disclosure is shown.

[0015] Figure 9A Shows Figure 9 An enlarged view of a part of the partial cross-sectional view shown in

[0016] Figure 10 Shows an enlarged partial cross-sectional view taken substantially along Figure 9 Line 10-10, showing a cross-sectional configuration of a modified shape of a first member having a reinforcing member.

[0017] Figure 11 Shows a similar enlarged partial cross-sectional view according to an exemplary embodiment of the present disclosure Figure 10 But shows a first member without a reinforcing member.

[0018] Figure 12 Shows an exploded isometric view of a part of a polyurethane screen according to an exemplary embodiment of the present disclosure, which has a reinforcing member integral with the first and second members.

[0019] Figure 13 Shows an exploded view of the use of a screen basket according to an exemplary embodiment of the present disclosure in an embodiment of a screening device.

[0020] Figure 14 Shows a side cross-sectional view of an exemplary embodiment of the use of a screen basket in an embodiment of a screening device according to an exemplary embodiment of the present disclosure.

[0021] Figure 15 Shows a perspective view of an example of a cage according to an exemplary embodiment of the present disclosure.

[0022] Figure 16A Shows a perspective view of an exemplary screen basket according to an exemplary embodiment of the present disclosure, the exemplary screen basket including a plurality of screening filter element assemblies attached to the cage.

[0023] Figure 16B Shows according to an example embodiment of the present disclosure Figure 16A A partial perspective view of the screen basket shown in

[0024] Figure 16C Shows according to an example embodiment of the present disclosure Figure 16A A partial perspective view of the interior of the screen basket shown in

[0025] Figure 17 Shows a partial cross-sectional view of an exemplary screening filter element assembly mounted on a grille frame according to an exemplary embodiment of the present disclosure.

[0026] Figure 18A Shows a perspective view of an example of a screening filter element assembly according to an exemplary embodiment of the present disclosure.

[0027] Figure 18B Shows Figure 18A A cross-sectional view and a side view of the exemplary screening filter element assembly shown. 18A. Example dimensions are shown in inches in the views. The present disclosure is not limited to such dimensions, and other dimensions are contemplated.

[0028] Figure 19A A perspective view of an example of a housing of a screening filter element assembly according to an exemplary embodiment of the present disclosure is shown.

[0029] Figure 19B Shows Figure 19A A cross-sectional view and a side view of the exemplary housing shown. Example dimensions are shown in inches in the views. The present disclosure is not limited to such dimensions, and other dimensions are contemplated.

[0030] Figure 19C Examples of a plurality of housings of a grille frame fixed to a basket cage according to an exemplary embodiment of the present disclosure are shown.

[0031] Figure 20A An example of a sieve assembly element according to an exemplary embodiment of the present disclosure is shown.

[0032] Figure 20B Shows Figure 20A A cross-sectional view and a side view of the exemplary sieve assembly element shown. Example dimensions are shown in inches in the views. The present disclosure is not limited to such dimensions, and other dimensions are contemplated.

[0033] Figure 21A A perspective view of an example of a frame unit of a sieve assembly according to an exemplary embodiment of the present disclosure is shown.

[0034] Figure 21B Shows Figure 21A A top view and a side view of the exemplary frame unit shown.

[0035] Figure 22A An example of a sieve element of a sieve assembly according to an exemplary embodiment of the present disclosure is shown.

[0036] Figure 22B Shows Figure 22A A top view and a side view of the exemplary sieve element shown.

[0037] Figure 23A Another example of a sieve assembly element according to an exemplary embodiment of the present disclosure is shown.

[0038] Figure 23B Shows Figure 23A A side view of the exemplary sieve assembly element shown.

[0039] Figure 24 Shows an example of a filter element screen according to an example embodiment of the present disclosure.

[0040] Figure 25 Shows Figure 25 An example of the bottom shell portion of the filter element screen shown in Detailed Description of the Invention

[0042] The present disclosure relates to devices and methods for filtration, and particularly to the use of an improved sieve basket for use in methods and systems for adsorbing metals from metal-containing ores. Embodiments of the present disclosure can be used with carbon-in-pulp (CIP), carbon-in-leach (CIL), and resin-in-leach (RIL) systems. CIL and CIP systems are, for example, two countercurrent methods for adsorbing leached gold in a slurry stream onto activated carbon. In such CIL and CIP processes, multiple adsorption tanks are placed in series. The slurry continuously flows from the first tank in the series to the last tank. At the same time, carbon is pumped countercurrently from the last tank in the series to the first tank. CIP and CIP processes differ in the degree of gold leaching before carbon adsorption. For example, in a CIL operation, carbon is added to the leaching tank, and the leaching reaction and adsorption occur simultaneously. In contrast, in a CIP process, most of the leachable gold is leached before the first adsorption stage.

[0043] A description of a general method for recovering gold from gold-containing ores using a combination of cyanidation and adsorption treatment can be found in U.S. Patent No. 4,188,208. Although embodiments of the present disclosure are generally discussed with reference to gold or carbon, embodiments of the present disclosure can be equivalently applied to the process of recovering silver, iron, nickel, and other metals from suitable ores. The recovery of any metal from mined ores is within the scope of the present disclosure.

[0044] A description of existing metal screening baskets and their method of use in the above CIP process can be found in U.S. Patent 5,238,117. The method described in U.S. Patent 5,238,117 is commonly referred to in the art as the "NKM" vertical sweep interstage screening process, and the screening basket used therein is commonly referred to in the art as an NKM screening basket. Generally, such an NKM screening basket includes a metal support frame provided with a wedge-shaped wide screen wrapped around its peripheral sidewall. The wedge wire screen is used to filter materials from a metal-rich slurry. The screening basket is attached to an NKM screening device, and the lower part of the NKM screening device (including the attached NKM screening basket) is immersed in a tank containing the carbon material in the slurry. The impeller on the NKM screening device causes the slurry in the tank to pass through the wedge wire screen and into the interior of the NKM screen. However, the open screening area of the wedge wire screen is very small, resulting in low screening efficiency. The low open screening area also causes clogging. The clogging in turn forces an increased volume of slurry to flow through the unclogged areas of the wedge wire screen, which increases the wear rate of the screen. Additionally, due to the forces encountered during the screening process, such as the sweeping of the internal and external propulsion blades, the individual metal wires forming the wedge wire mesh can deteriorate or break over time.

[0045] In an exemplary embodiment of the present disclosure, an improved screening basket device for screening materials is provided. The device includes a support frame having a substantially closed bottom and an open top, and a substantially cylindrical sidewall retainer frame portion extending between the bottom and the top of the support frame. The support frame can be metal, such as stainless steel. A polyurethane screen sidewall extends around the sidewall retainer frame portion and is supported by the sidewall retainer frame portion. The polyurethane screen sidewall includes a polyurethane screen with a high open area. In certain embodiments, the polyurethane screen sidewall substantially encloses the sidewall retainer frame portion between the closed bottom and the open top, thereby providing a maximum screening area. The polyurethane screen sidewall can be fixed to the outer periphery of the sidewall retainer frame portion.

[0046] The polyurethane screen sidewall can be formed by a plurality of individual polyurethane screen members. These individual polyurethane screen members can be aligned adjacent to each other to provide a generally continuous screening area on the screen sidewall. In one example, the plurality of individual polyurethane screen members can include eight individual polyurethane screen members. In such an embodiment, the eight individual polyurethane screen members can be arranged such that four of the screen members are on the lower half of the support frame and four of the screen members are on the upper half of the support frame.

[0047] In certain embodiments, the substantially closed bottom can be provided with a central hole that allows for the receipt of the drive shaft of the NKM device.

[0048] In some embodiments, the high open area polyurethane screen member includes a flexible molded polyurethane body; screen openings within the body; a first set of substantially parallel flexible members that define opposite first sides of the screen openings; a second set of substantially parallel flexible members that define second opposite sides of the screen openings, whereby the second members are substantially perpendicular to the second members; a third set of substantially parallel members with a plurality of first members therebetween; a fourth set of substantially parallel members with a plurality of second members therebetween; side edge portions that are substantially parallel to opposite sides of the body, wherein the third members extend between opposite sides of the body; a first end and a second end that are substantially parallel at opposite ends of the body, wherein the fourth members extend between opposite ends of the body such that the ends are substantially perpendicular to the edge portions. The screen openings in the flexible molded polyurethane body of the polyurethane screen member can be from about 0.044 mm to about 4.000 mm between the inner surfaces of the first members and can be from about 0.044 mm to about 60.000 mm between the inner surfaces of the second members.

[0049] The polyurethane screen member can further include reinforcing members integrally formed within at least one of the first and third members and at least one of the second and fourth members. In some embodiments, the reinforcing member integrally formed within the first member can have a substantially uniform thickness that is sized in the range of from about 0.006 inches to about 0.015 inches. The reinforcing member integrally formed with the second member can have a substantially uniform thickness that is sized in the range of from about 0.015 inches to about 0.040 inches. The reinforcing member can be embodied as, for example, a rod that can be integrally molded with the member. The reinforcing member can also be embodied in, for example, aramid fibers, which are at least one of twisted and braided multi-strand fibers having a linear density of from about 55 denier to about 2840 denier.

[0050] The side edge portions of the polyurethane screen member can be configured to attach the screen member to a support frame. A plurality of enlarged polyurethane ribs can be integrally formed on the outer surface of the polyurethane screen body, and the ribs are arranged substantially perpendicular to the sidewall retainer frame portion. Each of the plurality of ribs can extend substantially from the top to the bottom of the polyurethane screen member.

[0051] In other embodiments of the present disclosure, a basket cage can be provided, which includes a tubular or substantially cylindrical grille frame having a plurality of openings. The plurality of openings in the grille frame can be arranged in a square lattice, and each of the plurality of openings (or in some embodiments, at least some of them) can have a square shape. In an exemplary embodiment, the plurality of openings can include 264 square openings. A subset of the plurality of openings can be defined by longitudinal members and transverse members. A second subset of the plurality of openings can be defined by the longitudinal members of the grille frame and the transverse segments of the first annular portion, and similarly, a third subset of the plurality of openings can be defined by the longitudinal members of the grille frame and the transverse segments of the second annular portion.

[0052] The basket cage can have flanges at the top and bottom of the cage. The top flange and the openings can allow or otherwise facilitate the installation of a plate or another type of cover on the flange. Additionally or in other embodiments, the flanges and the openings can allow or otherwise facilitate the installation of the basket cage into a screen separator (e.g., an NKM vertically swept interstage device).

[0053] The basket cage can be used in a separation process to separate specific particulate matter from a slurry or another type of fluid source. For this purpose, in one embodiment, a screening filter element assembly can be installed in the basket cage, where the screening filter element assembly can allow or otherwise facilitate the separation of specific particulate matter from the slurry. Each of the screening filter element assemblies can be installed or otherwise fixed to a corresponding set of grille members that at least partially define the corresponding openings of the grille frame. For the openings arranged in rows around the longitudinal axis of the grille frame, the set of grille members supporting the first of the screening filter element assemblies can have a common grille member, and another set of grille members supports the second of the screening filter element assemblies.

[0054] In some embodiments, each of the plurality of screening filter element assemblies installed or fixed to the grille frame includes a screen assembly and a housing (or another type of container) configured to receive and hold the screen assembly. In some embodiments, the housing can be embodied as a single injection molded part integrally formed by injection molding polyurethane, a thermosetting polymer, or another type of polymer. Exemplary embodiments of injection molded parts and the process of forming injection molded parts are discussed in more detail in U.S. Patent Application 13 / 800,826, U.S. Patent 9,409,209, U.S. Patent 9,884,344, U.S. Patent Application 15 / 851,009, U.S. Patent Application 15 / 965,195, and the disclosures included in the cross-references therein, the entire contents of which are incorporated herein by reference.

[0055] In some embodiments, the sieve assembly has three separate sieve units. The housing includes a first opening configured to receive and / or fit the sieve assembly within the housing, and a second opening that allows the sieve surface of the sieve assembly to be exposed to the exterior of the grille frame. The housing also includes a ridge extending from a first edge of the housing near the first opening to an opposite second edge of the housing. The ridge and respective portions of the housing form respective notches that allow or otherwise facilitate mounting (e.g., gripping or clamping) of the housing to the grille frame.

[0056] During the operation of the separation process, all or substantially all of the grille frame of the sieve basket can be covered by the screening filter element assembly. Thus, in an exemplary embodiment, 264 screening filter element assemblies can be installed into each of the 264 square openings in the grille frame.

[0057] In addition, the housing can include an attachment frame portion and a retainer frame portion. The retainer frame portion can accommodate and / or hold the sieve assembly formed by the sieve units. The attachment frame portion can include a set of ridges that form respective notches, which in turn allow or otherwise facilitate (e.g., by clamping, gripping, or otherwise engaging) attachment of the screening filter element assembly to the grille frame.

[0058] The sieve filter element according to the present disclosure can be of any suitable shape for attachment to the grille frame of the basket cage. By way of example and not limitation, the sieve filter element can be square, or rectangular, or oval, or any other shape. Although exemplary embodiments can provide a sieve filter element whose shape substantially matches the grille openings of the grille frame (i.e., a square sieve filter element on a grille frame with square grille openings), sieve filter elements of different shapes can be secured to grille openings of different shapes. Similarly, the grille frame of the basket cage can have any suitable shape for screening.

[0059] The sieve element and sieve filter element according to the embodiments discussed herein resist wear, abrasion, bending, and chemical corrosion better than metal, and thus have a longer life than wedge wireframes in the CIL process. Compared to conventional wedge wireframes, the sieve elements discussed herein also allow the formation of significantly smaller sieve apertures, which in turn improves screening efficiency. Compared to conventional wedge wire sieve baskets, the use of the sieve members described herein provides a significantly larger screening area and significantly reduces sieve blinding. In use, the sieve elements and sieve filter elements described herein also allow the distance between the external propulsion vanes of the screening device and the screening filter element assembly to be substantially uniform, thereby reducing clogging and extending the life of the sieve elements.

[0060] Now referring to Figures 1 to 5 the illustrated embodiment, the sieve basket 1 of the present disclosure includes a basket frame structure 510 to which a high open area polyurethane sieve 600 is attached.

[0061] As Figure 1As shown, the basket 510 generally has a cylindrical configuration, although other shapes may be used. The basket 510 may preferably be formed of stainless steel, although other materials may be used. The frame has an upper end 511 and a lower end 515 and includes a plurality of vertical support members 530 forming a vertical retainer frame portion extending between the upper end 511 and the lower end 515 of the frame 510. As Figure 2 shown, the vertical retainer frame portion of the frame 510 has an inner side 521 and an outer side 522.

[0062] As Figure 3 shown, the support of the basket 510 may be formed by a plurality of vertical support members 530 and a plurality of horizontal support members 550. Figure 3 The illustrated embodiment includes four main support members 531 spaced along the perimeter of the frame 510 and a plurality of secondary support members 542 spaced between the main support members 531. The main and secondary support members 531, 542 are connected in a spaced arrangement to connect the upper and lower ends 511, 515 of the frame 510. The horizontal support members 550 may be provided by a plurality of annular rings or curved portions that are connected end to end to form a plurality of annular rings in a spaced relationship throughout the basket 510.

[0063] As Figure 3 shown, each vertical support member 531 may include an inner pillar portion 532. The inner pillar portion 532 may in turn include a hole 534 therethrough. The horizontal support member 550 passes through the hole 534, thereby holding the horizontal support members 550 in a stacked and spaced arrangement.

[0064] As Figure 2 shown in the top view, the upper end 511 of the frame 510 is provided with an opening to allow for the receipt and processing of the material within the sieve basket 1. The lower end 515 of the frame 510 is provided with a substantially solid or closed bottom 516 for holding the material in the sieve basket 1 during the processing. The substantially closed bottom 516 may be provided with a central hole 517 for operative arrangement with the shaft of the processing machine, as discussed in more detail below.

[0065] Embodiments of the present disclosure may include a polyurethane screen 600 attached to the periphery of the frame 510 in a high open area, thereby forming a sieve basket 1 having an open top, a substantially solid or closed bottom 516, and polyurethane screen sidewalls 601.

[0066] Due to potential dimensional limitations during the molding process of the polyurethane screen 600, the polyurethane screen 600 may be provided in the form of separate, smaller screen members 10. For example, as Figure 1 shown in the illustrated embodiment, the polyurethane screen 600 may have a plurality of separate screen members 10. Each screen member 10 is attached to a vertical support of the frame 510.

[0067] Figures 4 to 6 Illustrates features of an exemplary embodiment of a screen member 10 configured to form a polyurethane screen sidewall 601 of a screen basket 1. Figures 4 to 5 The outer and inner sides of an embodiment of the screen member 10 are shown respectively, while Figure 6 A side view of an embodiment of the screen member 10 is shown. The screen member 10 may include a polyurethane screen, which is described in more detail in the following patents and patent publications, which have the same assignee as the present disclosure and are incorporated herein by reference: U.S. Patent No. 8,584,866; U.S. Patent No. 9,010,539; U.S. Patent No. 9,375,756; U.S. Patent No. 9,403,192; U.S. Patent Application Publication No. 2015 / 0197827A1; and U.S. Patent Application Publication No. 2016 / 0303611A1.

[0068] As Figures 4 to 7 shown, embodiments of the present disclosure may provide a screen member 10 having a body 12 molded from polyurethane and having unperforated side edge portions 14, 16. The side edge portions 14, 16 may each have an integral side ridge portion 29 for sealing adjacent screen members 10 to each other and securing the screen member 10 to a basket frame 510, as Figure 7 shown. Each side edge portion 14, 16 may include a cast-in structural member for reinforcing the side ridge portion 29. The side edge portions 14, 16 may also be formed without a cast-in structural member or may include other structural members. The side ridge portion 29 may have any suitable shape for attachment to the basket frame 510. In an exemplary embodiment, the side ridge portion 29 may include a shaped member, such as a metal member bent into a desired shape, such as a U-shaped member, an L-shaped member, a C-shaped member, etc. The shaped member may be attached to the polyurethane body by heating, pressing, mechanical, chemical, molding, and / or any other suitable method or arrangement.

[0069] The body 12 of the screen member 10 further includes a lower edge portion 18 and an upper edge portion 20, which in combination with the side edge portions 14, 16 define the outer boundary of the screen member 10. In certain embodiments, the side ridge portion 29 may extend the entire length between the upper edge portion 20 and the lower edge portion 18.

[0070] The body 12 further includes an outer surface 22 and an inner surface 24. Figure 4 Depicts the outer surface 22 of the body 12 when the screen member 10 is secured to the basket frame 510, for example, as Figure 1 shown, Figure 5 Depicts the inner surface 24 of the body 12 when the screen member is secured to the basket frame 510, as Figure 1as shown. The body 12 includes a first member 101 and a second member 102 that form the sieve holes 26, as Figure 8 and Figure 8A shown in detail therein. In some embodiments, the first member 101 and the second member 102 may be configured to include a reinforcing member 50, as discussed in more detail below. As Figure 6 shown in the side view of, the sieve element 10 may also include vertical ribs 28 on the outer surface 22 of the sieve element 10. However, in certain embodiments of the present disclosure, the sieve element 10 may not include the vertical ribs 28.

[0071] The body 12 may further include a third member 203 and a fourth member 204. The third member 203 and the fourth member 204, as well as the vertical ribs 28 (if present), may also include a reinforcing member 50, which will be discussed in more detail below. However, in certain embodiments of the present disclosure, the third member 203, the fourth member 204, and the vertical ribs 28 may not include the reinforcing member 50. The third member 203 and the fourth member 204 are generally configured to provide support to the sieve holes 26 formed by the first member 101 and the second member 102.

[0072] Figure 8 A portion of an embodiment of the sieve element 10 is shown, Figure 8A depicting Figure 8 an enlarged view of a portion of. As Figure 8A shown in the detailed view of, the first and second members 101, 102 form a first integrally molded grid structure 100 that defines the sieve holes 26. The third and fourth members 203, 204 may respectively form a second integrally molded grid structure 200, and the fifth and sixth members 305 and 306 may respectively and sequentially form a third integrally molded grid structure 300.

[0073] The reinforcing member 50 may be incorporated into the desired members of the sieve element 10. The reinforcing member 50 provides stability to the sieve element 10 by preventing the side edges 14, 16 from deforming and / or hourglassing. In an exemplary embodiment, the reinforcing member 50 may be combined with the appropriate members (e.g., by integral molding). The reinforcing member 50 may be made of plastic, metal, polymer, or any other suitable material having the necessary structural properties. For example, the reinforcing member 50 may be embodied as a rod integrally molded with the sieve member. The reinforcing member 50 may also be embodied as an aramid fiber, which is at least one of a twisted multi-strand yarn and a braided multi-strand yarn, such that the fiber acts as a core to absorb the polyurethane molded around it, thereby providing a firm bond therewith. The linear density of the twisted or braided multi-strand fiber may be from about 55 denier to about 2840 denier, and may preferably be about 1500 denier. When aramid fibers are used in the embodiments of the present disclosure, it may be capable of being trademarked by DuPont A commercially available set of aromatic polyamide fibers. The reinforcing member 50 can also be at least one aromatic polyamide fiber, which can be commercially obtained under the trade names TWARON, SULFRON, TEIJINCONEX, and TECHNORA of Teijin Limited. The flexibility of the aromatic polyamide fibers provides a flexible reinforcement system for the molded polyurethane, which can return to its original molded shape after undergoing the necessary bending and flexing during handling and installation. In certain embodiments, the reinforcing member 50 can be tensioned before the polyurethane is molded around it.

[0074] Return to reference Figures 4 to 5 in the exemplary embodiments shown, and Figure 8 in the detailed views shown, the grille structures 200 and 300 include a two-way integrally formed member that forms a support grille within the member. Due to the characteristics of the reinforcing member 50 and the construction of the two-way grille structure, the member can have a relatively small size and thus provide an increased open screening area. The grille structure provides screen strength and support for the openings 26 during vibration loads and significantly increases the open screening area.

[0075] As Figure 8A shown in the detailed view of, the first member 101 can extend laterally between the side edge portions 14, 16 in a substantially parallel manner to each other. The second member 102 can extend laterally between the lower edge portion 18 and the upper edge portion 20 in a substantially parallel manner to each other and substantially perpendicular to the first member 101. In certain embodiments, the thickness of the second member 102 can be greater than the thickness of the first member 101 to provide additional structural support for the sieve holes 26.

[0076] As described above, and as Figure 12 shown in the exploded perspective view of, the first member 101 and / or the second member 102 can include the reinforcing member 50 and can be or can not be supported by additional support members or support grille structures. For example, as Figure 9 shown, which depicts a partial cross-sectional view of the body 12 of the sieve member 10, the body 12 having the first and second members 101, 102, and the two-way reinforcing member 50 is integrally formed with the first and second members 101, 102. The thickness of the reinforcing member 50 integrally formed with the first member 101 is in the range of approximately 0.006 inches to approximately 0.015 inches. The reinforcing member 50 (not shown) integrally formed with the second member 102 has a thickness in the range of approximately 0.015 inches to approximately 0.040 inches. Such a configuration may be beneficial for screening applications of sieves that require larger sieve holes.

[0077] Embodiments of the present disclosure may incorporate the reinforcing member 50 and the ribs 28 in any one of the first, second, third, and fourth members 101, 102, 203, 204, and may be incorporated into all or a portion of the first, second, third, and fourth members 101, 102, 203, 204 and the rib member 28.

[0078] As Figure 8 and Figure 8A shown in the detailed view of, the sieve holes 26 may be elongated, with the length dimension between its sides and ends being greater than the width dimension. The width of the sieve holes 26 may be from about 0.044 mm to about 4.0 mm, and the width is the dimension between the inner surfaces of the adjacent first members 101. The length of the sieve holes 26 may be from about 0.44 mm to about 60 mm, and the length is the dimension between the inner surfaces of the adjacent second members 102. The sieve holes 26 may additionally have various different shapes. For example, the sieve holes 26 may have a rectangular, or square, or oval shape, or any other shape formed by the first member 101 and the second member 102. The overall size of the sieve element 10 may be about 1.2 meters x 1.6 meters, or may be any other desired size. It is understood that all the dimensions set forth herein are merely exemplary and not restrictive.

[0079] Briefly referring to Figure 10 and Figure 11 , the sieve holes 26 may fork downward between the outer surface 22 and the inner surface 24, and the first member 101 is substantially in an inverted trapezoidal shape. This generally trapezoidal shape of the first member 101 prevents sieve blockage in the sieve element 10 and the entire polyurethane sieve 600. The first member 101 may include the reinforcing member 50 integrally formed therewith, as Figure 10 shown, or optionally may not include the reinforcing member 50 integrally formed therewith, as Figure 11 shown.

[0080] As Figure 8A shown in the detailed view of, the thickness of the third and fourth members 203, 204 may be greater than the thickness of the first and second members 101, 102. The increased thickness of the third and fourth members 203, 204 may provide additional structural support for the first and second members 101, 102. In Figure 8 and 8AIn an exemplary embodiment, the third member 203 may extend laterally between the side edge portions 14, 16 in a substantially parallel manner to each other, and may have a plurality of first members 101 therebetween. The fourth member 204 may extend laterally between the lower edge portion 18 and the upper edge portion 20 in a substantially parallel manner to each other, and may have a plurality of second members 102 therebetween. The reinforcing member 50 may be integrally formed with the third and fourth members 203, 204. The third and fourth members 203, 204 may be configured to have a minimum thickness by including the reinforcing member 50 while maintaining the necessary structural support for the sieve holes 26 formed by the first and second members 101, 102 during the vibratory screening application. The bi-directional support system provided by the third and fourth members 203, 204 and the additional support of the reinforcing member 50 integrated therein (if included) greatly reduces the thickness of the support members and provides an increased open screening area and overall screening efficiency.

[0081] The body 12 may further include a plurality of vertical ribs 28. In Figures 4 to 6 the illustrated embodiment, a series of nine ribs 28 may be provided. The thickness of the ribs 28 may be greater than the thickness of the third and fourth members 203, 204, and may have portions extending away from the inner surface 24 of the body 12. As Figure 2 illustrated, ribs 28 may also be provided that extend away from the outer surface 522 of the body 12 and thus provide vertical support along the outer sieve sidewall 601. The greater thickness and positioning of the ribs 28 provide additional structural support for the first and second members 101, 102.

[0082] The ribs 28 may extend laterally between the lower edge portion 18 and the upper edge portion 20 in a substantially parallel manner to each other, and may have a plurality of fourth members 204 therebetween. The ribs 28 may alternatively or additionally extend laterally between the side edge portions 14, 16 in a substantially parallel manner to each other, and may have a plurality of third members 203 therebetween. The ribs 28 may have a reinforcing member 50 integrally formed therein. The ribs 28 may be provided for additional support of the sieve holes 26, and may be configured to have a minimum thickness by including the reinforcing member 50 while providing the necessary structural support to maintain the sieve holes 26 during the vibratory screening application. Like the third and fourth members 203, 204, the support system provided by the ribs 28 greatly reduces the thickness of the support members and provides an increased open screening area and overall screening efficiency.

[0083] Various configurations of the reinforcing member 50 may be provided in the support rib members 28 to increase the stability of the sieve member 10. The reinforcing member 50 provided in the support rib members 28 may be aramid fibers (or individual filaments thereof), naturally occurring fibers, or other materials having a relatively large tensile strength and a small cross-sectional area.

[0084] Each element of the sieve element 10 that is capable of binding to such a reinforcing member 50 may include zero, one, or more reinforcing members 50, and the reinforcing members 50 used therein may have different sizes and materials. The reinforcing member 50 may be located in the lower half of the member so as not to be exposed relatively early during the service life of the sieve element 10, since the upper surface of the sieve may wear.

[0085] A support frame including the reinforcing member 50 and a bi-directional support member such that the first member 101 and the second member 102 are relatively thin, thereby forming relatively large sieve apertures. The embodiments described herein have a relatively high tensile strength and a relatively small cross-sectional area. The manufacture of the support member and the thin first member 101 results in a sieve member 10 and an overall sieve 600 having a greater percentage of open area, which in turn increases the capacity of the system. The range of the open screening area according to the embodiments described herein may be, for example, from about 40% to about 46% of the sieve.

[0086] According to an embodiment of the present disclosure, the vibrating screen 10 includes a flexible molded polyurethane body 12 having substantially parallel side edge portions 14, 16 at opposite ends of the body 12, a lower edge portion 18 substantially perpendicular to the side edge portions 14, 16, and an upper edge portion 20 substantially perpendicular to the side edge portions 14, 16 and opposite the lower edge portion 18. The polyurethane body 12 further includes an outer surface 22 and an inner surface 24. First and second members 101, 102 are provided to form sieve holes 26. The first member 101 extends between the side edge portions 14, 16, and the second member 102 extends between the lower edge portion 18 and the upper edge portion 20. The body 12 may further include third and fourth members 203, 204, the thickness of the third and fourth members 203, 204 being greater than the thickness of the first and second members 101, 102. The third member 203 extends substantially parallel to each other and transversely between the side edge portions 14, 16 and has a plurality of first members 101 therebetween. The fourth member 204 extends substantially parallel to each other and transversely between the lower edge portion 18 and the upper edge portion 20 and has a plurality of second members 102 therebetween. The reinforcing member 50 may be integrally formed with the third and / or fourth members 203, 204, and additionally, the reinforcing member or rod may be integrally formed with the fourth member 204. The body 12 further includes ribs 28. The ribs 28 may extend substantially parallel to each other and transversely between the side edge portions 14, 16. The ribs 28 extend substantially parallel to each other and transversely between the lower edge portion 18 and the upper edge portion 20. The thickness of the ribs 28 is greater than the thickness of the third and fourth members 203, 204 and may include a reinforcing member 50 integrally formed therewith. The body 12 may additionally have fifth and sixth members 305, 306. The fifth member 305 extends substantially parallel to each other and transversely between the side edge portions 14, 16 and has a plurality of third members 203 therebetween. The sixth member 306 extends substantially parallel to each other and transversely between the lower edge portion 18 and the upper edge portion 20 and has a plurality of fourth members 204 therebetween. The reinforcing member 50 may be integrally formed with the fifth and / or sixth members 305, 306, and additionally, the reinforcing member or rod may be integrally formed with the sixth member 306.

[0087] The screen member according to this embodiment may have an open screening area of greater than 40%, and the mesh size ranges from approximately 0.375 mesh to approximately 400 mesh. For example, the tested screen meshes having the above configuration include a 43-mesh screen, a 140-mesh screen, and a 210-mesh screen. Each of these screen meshes has an open screening area of about 40% to about 46%. Such a large screening area for such a relatively fine screen hole size is achieved by the relatively strong and thin grid frame formed by the third, fourth, fifth, and sixth members 203, 204, 305, 306 and the reinforcing members integrally formed therewith.

[0088] In the foregoing embodiments and examples, the size of each grid unit formed by the intersection of the third member 203 and the fourth member 204 is approximately 1 inch by 1 inch. Generally, for screens with larger screen holes, the grid units can be larger, while for screens with smaller screen holes, the grid units can be smaller. This principle generally applies to each exemplary embodiment discussed herein. The grid units may also have a generally rectangular shape, or may have any other suitable shape for supporting the screen holes.

[0089] Using the polyurethane screen member 10 described herein to form the screen sidewall 601 on the basket has significant advantages over conventional wedge wire screens. The polyurethane screen member 10 described herein has better resistance to wear, abrasion, bending, and chemical corrosion than metal, and thus has a longer service life than the wedge wire frame in the CIL process. Compared with the traditional wedge wire frame, polyurethane also allows the formation of significantly smaller screen holes, thereby improving the screening efficiency. Compared with the conventional wedge wire screen basket, the use of the polyurethane screen member 10 described herein provides a significantly larger screening area and significantly reduces screen clogging.

[0090] In operation, the screen basket 1 described herein can be used with known CIP and CIL equipment and processes, such as those described in U.S. Patent No. 5,238,117. For example, as Figures 13 to 14 shown, the screen basket 1 is attached below the volute portion of the NKM vertical sweep interstage device. The drive shaft of the NKM device passes from the top to the bottom of the screen basket 1 and passes through the central opening that closes the bottom of the screen basket 1. The gearbox and motor are located above the volute to provide power to the drive shaft. The wash interface is located above the polyurethane screen and volute interface to receive the pulp discharge flow.

[0091] In the case where the sieve basket 1 is attached to the NKM device, the lower part of the NKM device including the sieve basket 1 is inserted and suspended on a large adsorption tank containing the pulp to be processed. The level of the pulp in the tank is higher than the fluid level in the sieve basket 1. This arrangement allows the pulp to flow naturally through the screen of the sieve basket 1 in an attempt to equalize the fluid levels in the pulp tank and the sieve basket 1. The outer blades outside the NKM unit rotate around the outer periphery of the sieve side wall of the sieve basket 1 inside the tank. The outer blades also help prevent particles from clogging the outside of the polyurethane sieve, such as by carbon and pulp. The pulse and sweep actions reduce the likelihood of carbon and materials of near-standard size blocking the sieve holes. The impeller blades located inside the screen (such as the drive shaft) can be used to keep the particles in suspension and push the pulp upward towards the volute and the wash tank.

[0092] During this process, the pulp flows upward through the inside of the sieve basket 1. The carbon is retained in the sieve. The pulp exists through the wash interface located above the interface between the polyurethane sieve and the volute.

[0093] During these processes, it can be seen that the continuous rotation of the inner and outer blades near the polyurethane sieve, and the large amount of pulp flowing through the openings of the polyurethane sieve, subject the sieve to considerable wear. The arrangement of the polyurethane sieve and the sieve basket described herein is designed to withstand significant wear and is significantly superior to existing wire mesh sieve baskets in CIP and CIL processes.

[0094] Although the sieve basket 1 has been described for use in CIP or CIL processes, the relatively small openings and relatively large screening area of the polyurethane sieve member 10 described herein allow the sieve basket 1 to be used for other purposes, such as water filtration and desalination.

[0095] Figure 15A perspective view of an example of a basket cage 1500 according to another embodiment of the present disclosure is shown. The basket cage 1500 includes a grille frame 1510 that is tubular (or has substantially cylindrical symmetry) relative to a longitudinal axis and has a plurality of openings 1513. Thus, the grille frame 1510 has a height and a diameter. As an example, the size of the height can range from about 23 inches (about 58 cm) to about 122 inches (about 310 cm). As another example, the size of the diameter can range from about 10 inches (about 25.4 cm) to about 73 inches (about 185.4 cm). In an example embodiment, the size of the height is about 80 inches (about 203.2 cm) and the size of the diameter is about 50 inches (about 127 cm). Note that the present disclosure is not limited to such illustrative sizes of the height and / or diameter, and other dimensions of the grille frame 1510 are contemplated. Additionally, the grille frame 1510 is not limited to being tubular or cylindrically symmetric, but can be formed in any configuration suitable for sieving and particularly carbon retention sieving as discussed herein. The grille frame 1510 can also be formed from any material that provides sufficient structure for the sieving process and sufficient support for the sieving filter elements to be attached to the grille frame 1510. For example, the grille frame 1510 can be formed from a metal or metal alloy, such as stainless steel, or can be a thermoplastic material sufficient to support the sieving filter elements. In an embodiment featuring a thermoplastic grille frame 1510, the grille frame 1510 can include a single injection molded piece. In other embodiments, the grille frame 1510 can be formed from separable pieces that are joined together to form the grille frame 1510.

[0096] In some embodiments, the grille frame 1510 can be formed into a desired shape by bending a perforated sheet around a longitudinal axis onto itself and joining opposite edges of the perforated sheet. The joined opposite edges can form a longitudinal seam 1515. In some embodiments, the perforated sheet can be formed of metal or a metal alloy (e.g., stainless steel), and the opposite edges can be joined by welding. In other embodiments, the perforated sheet can be formed of rigid plastic, and the opposite edges can be joined by laser welding and / or bonding with a suitable adhesive. The plurality of openings 1513 in the grille frame 1510 can be arranged in a square grid, and each (or in some embodiments, at least some) of the plurality of openings 1513 can have a square shape. The plurality of openings 1513 can have other shapes than square, such as rectangular, oval, circular, etc. Moreover, it is not required that the plurality of openings 1513 have a consistent shape throughout the grille frame 1510. For example, some embodiments can have alternating rectangular openings of varying sizes to form the entire grille frame 1510. In an example embodiment, the plurality of openings 1513 can include 264 square openings. A subset of the plurality of openings can be defined by longitudinal members 1511 and transverse members 1512. The openings in such a subset can be referred to as internal openings. A second subset of the plurality of openings can be defined by the longitudinal members 1511 of the grille frame 1510 and the transverse segments of a first annular portion 1512a. Similarly, a third subset of the plurality of openings can be defined by the longitudinal members 1511 of the grille frame 1510 and the transverse segments of a second annular portion 1512b. The second and third subsets of openings can be referred to as external openings.

[0097] The first annular portion 1512a and the second annular portion 1512b can embody or otherwise form the respective opposite ends of the grille frame 1510 along the longitudinal axis. A flange 1520 can be fixed or otherwise attached to the end of the first annular portion 1512a. The flange 1520 can include a plurality of first openings 1525. The flange 1520 and the first openings 1525 can allow or otherwise facilitate mounting a plate or another type of cover on the flange 1520. Additionally or in other embodiments, the flange 1520 and the first openings 1525 can allow or otherwise facilitate mounting the basket 1500 into a sieve separator (e.g., an NKM vertical sweep interstage device as shown in Figure 13 and Figure 14 ). Additionally, a second flange 1530 can be fixed or otherwise attached to the second annular portion 1512b. The second flange 1530 can include a plurality of second openings 1535. The flange 1530 and the second openings 1535 can allow or otherwise facilitate mounting the basket 1500 into a sieve separator (e.g., an NKM vertical sweep interstage device as shown in Figure 13 and 14the NKM vertical sweep interstage device shown), and / or an external wiper assembly (not shown) of a stationary screen separator.

[0098] As Figure 15 shown, the basket 1500 may also include an opening near the second end of the grille frame 1510, near the second flange 1530. The pipe member 1540 may be assembled near the opening. The opening and the pipe member 1540 may form an outlet that may allow or otherwise facilitate the outflow of the slurry from the interior of the basket 1500 when it is desired to discharge it during removal.

[0099] Similar to other screen baskets of the present disclosure, the basket 1500 in combination with the screen elements may be used to separate specific particulate matter from a slurry or another type of fluid source during the separation process. To this end, in one embodiment, a screen filter element assembly may be mounted to the basket 1500, where the screen filter element assembly may allow or otherwise facilitate the separation of specific particulate matter from the slurry. Specifically, by way of illustration, Figure 16A A perspective view of an example of a screen basket 1600 according to one or more embodiments of the present disclosure is shown, which includes a plurality of screen filter element assemblies 1610. The plurality of screen filter element assemblies includes a first screen filter element assembly 1610a, a second screen filter element assembly 1610b, and a third screen filter element assembly 1610c. Each of the screen filter element assemblies 1610a, 1610b, 1610c may be mounted or otherwise fixed to a respective set of grille members that define respective openings that at least partially define the grille frame 1510. The screen filter element assemblies 1610 may be removable, and thus, the screen filter element assemblies may be mounted to the basket 1500 and subsequently easily removed from the basket 1500 for maintenance or repair, or may be permanently fixed to the basket 1500. For rows of openings about the longitudinal axis of the grille frame 1510, a set of grille members that support the first of the screen filter element assemblies 1610a and 1610b may have a common grille member with another set of grille members that support the second of the screen filter element assemblies 1610a and 1610b. More specifically, in one example, the first screen filter element assembly 1610a may grip or otherwise attach to the first longitudinal member and the second longitudinal member of the grille frame 1510. Additionally, the second screen unit 1610b may grip or otherwise attach to the second longitudinal member and the third longitudinal member.

[0100] In some embodiments, each of the plurality of screening filter elements assemblies mounted or secured to the grille frame 1510 includes a screen assembly and a housing (or another type of container) configured to receive and hold the screen assembly. In some embodiments, the housing may be embodied as a single injection molded piece integrally formed by injection molding polyurethane, a thermosetting polymer, or other types of polymers. Example embodiments of injection molded pieces and the processes for forming injection molded pieces are discussed in more detail in U.S. Patent Application 13 / 800,826, U.S. Patent 9,409,209, U.S. Patent 9,884,344, U.S. Patent Application 15 / 851,009, U.S. Patent Application 15 / 965,195, and cross-references included therein, the entire contents of which are incorporated herein by reference. The housing and the screen assembly held therein may have any shape and structure suitable for mounting to the grille frame. In some embodiments, the housing and the screen assembly may be substantially rectangular. In other embodiments, the housing and the screen assembly may have a square shape, or may be oval-shaped, or may have a triangular shape, and so on.

[0101] As Figure 16B shown, the screening filter element assembly 1610a includes a housing 1630a and a screen assembly having three screen units 1640a. Note that the present disclosure is not limited to three screen units, and in some embodiments, fewer or additional screen units may be implemented. For a defined size of the screen units, a larger number of screen units results in a larger-sized housing 1630a, and thus a larger screening filter element assembly. The larger screening filter element assembly can be used in a grille frame with larger grille openings.

[0102] The housing 1630a includes a first opening configured to receive and / or fit the screen assembly within the housing 1630a. The housing 1630a also includes a second opening that allows the screening surface of the screen assembly to be exposed to the exterior of the grille frame 1510. The screening surface may be embodied as or may include, for example, a substantially seamless planar-type surface including a plurality of screen holes having, for example, substantially uniform dimensions and / or substantially uniform shapes. The plurality of screen holes may have a rectangular, square, circular, combinations thereof, and so on. Additionally, as Figure 16CAs shown, the housing 1630 further includes a ridge 1650a that extends from a first edge of the housing 1630a near the first opening to an opposite second edge of the housing 1630a. The ridge 1650a and corresponding portions of the housing 1630a form respective notches that allow or otherwise facilitate the mounting (e.g., gripping or clamping) of the housing 1630a to the grille frame 1510. The housing 1630a can be permanently mounted to the grille frame 1510 through the use of the ridge 1650a and various portions of the housing 1630a, or can be removably mounted to the grille frame 1510 such that the housing 1630a can be removed as needed for maintenance or repair.

[0103] Similarly, the screening filter element assembly 1610b includes a housing 1630b and a screening assembly having three screen units 1640b. As mentioned, the present disclosure is not limited to three screen units, and in some embodiments, fewer or additional screen units can be implemented. The housing 1630b further includes a first opening configured to receive and / or fit the screening assembly within the housing 1630b. The housing 1630b further includes a second opening that allows the screening surface of the screening assembly to be exposed to the exterior of the grille frame 1510. The screening surface can be embodied as or can include, for example, a substantially seamless planar-type surface including a plurality of screening holes having, for example, substantially uniform dimensions and / or substantially uniform shapes. Additionally, as Figure 16C shown, the housing 1630b further includes a ridge 1650b that extends from a first edge of the housing 1630b near the first opening to an opposite second edge of the housing 1630b. The ridge 1650b and various portions of the housing 1630b can form respective notches to allow or otherwise facilitate the mounting (e.g., gripping or clamping) of the housing 1630b to the grille frame 1510. Regarding the screening assembly received within the housing 1630b, as Figure 16C and Figure 17 further shown, each screen unit 1640b includes a frame unit having one or more screen elements fixed to the surface of the frame unit, and the screen units 1640b can be mechanically joined or otherwise fixed together to form the screening assembly. To this end, each screen unit 1640, as shown, for example, with reference to 1640b, can include one or more fasteners that can allow or otherwise facilitate fastening a first screen unit (e.g., screen unit 1640a) in the screen units to a second screen unit (e.g., 1640b) in the screen units. Regardless of the mechanism used to adjoin the screen units 1640b, the respective screen elements of the screen units 1640 can form a screening surface that can be exposed to the slurry outside the grille frame 1510.

[0104] In some embodiments, each (or in other embodiments, at least one) of the sieve elements may be embodied as a single injection molded piece integrally formed by injection molding of a thermoplastic material. Exemplary thermoplastic materials and processes for producing exemplary thermoplastic materials for use as sieve elements of the present disclosure are discussed in detail in U.S. Patent Application 13 / 800,826, U.S. Patent 9,409,209, U.S. Patent 9,884,344, U.S. Patent Application No. 15 / 851,009, U.S. Patent Application 15 / 965,195, and the disclosures of the cross-references included therein, the entire contents of which are incorporated herein by reference.

[0105] Similar to the screening filter element assemblies 1610a, 1610b, the screening filter element assembly 1610c also includes a housing 1630c and a sieve assembly having three sieve units ( Figure 16B (not shown in the figure). As mentioned, the present disclosure is not limited to three sieve units, and in some embodiments, fewer or additional sieve units may be implemented. The housing 1630c also includes a first opening configured to receive and / or fit the sieve assembly within the housing 1630c. The housing 1630c also includes a second opening that allows or otherwise facilitates exposing the screening surface of the sieve assembly to the exterior of the grille frame 1510. The screening surface may be embodied as, for example, within or may include a substantially seamless planar surface that includes a plurality of sieve apertures having, for example, substantially uniform dimensions and / or substantially uniform shapes. Additionally, as Figure 16C shown, the housing 1630c also includes a ridge 1650c that extends from the first opening of the housing 1630c near the first edge to the opposite second edge of the housing 1630c. The ridge 1650c and various portions of the housing 1630c form respective notches that allow or otherwise facilitate mounting (e.g., gripping or clamping) of the housing 1630c to the grille frame 1510. Figure 17 The mechanical coupling of the screening filter element assemblies 1610a and 1610b to the lateral grille members of the grille frame 1510 is shown. As described above, the ridge 1650a allows or otherwise facilitates mounting of the screening filter element assembly 1610a to the grille frame 1510. The ridge 1650b allows or otherwise facilitates mounting of the screening filter element assembly 1610b to the grille frame 1510.

[0106] The screening filter element assemblies 1610a and 1610b each include a respective screening assembly. According to the embodiments described herein, the screening assembly received in the filter element assembly 1610a includes three screen units 1640a. According to the embodiments described herein, the other screening assembly included in the filter element assembly 1610b also includes three screen units. As mentioned, the present disclosure is not limited to a screening assembly having three screen units, and in some embodiments, fewer or additional screen units may be implemented. Screening assemblies with different numbers of screen units may also be implemented.

[0107] Regarding the screening assembly received in the housing 1630c, as Figure 16C Further shown, each screen unit constituting the screening assembly includes a frame unit having a screen element attached to the surface of the frame unit. The screen units may be mechanically joined or otherwise fixed together to form a screening assembly. To this end, in one embodiment, each screen unit may include one or more fasteners that may allow or otherwise facilitate fixing the first screen unit in the screen units to the second screen unit in the screen units. Regardless of the mechanism used to adjoin the screen units, the respective screen elements of the screen unit 1640 may form a screening surface that can be exposed to the outside of the grille frame 1510.

[0108] Note that although three screening filter element assemblies are shown in Figures 16A to 16C and Figure 17 all or substantially all of the grille frame 1510 of the sieve basket 1600 may be covered for operation during the separation process. Thus, in an exemplary embodiment, in the embodiment of the grille frame 1510, 264 screening filter element assemblies may be installed in the corresponding 264 square openings 1513.

[0109] Figure 18A A perspective view of an example of a screening filter element assembly 1800 according to one or more embodiments of the present disclosure is shown. The exemplary screening filter element assembly 1800 includes a housing 1810 and a screening assembly having three screen units 1830. As mentioned above, the present disclosure is not limited to three screen units, and in some embodiments, fewer or additional screen units may be implemented. The housing 1810 has a generally arcuate shape and includes a first opening configured to receive and / or fit the screening assembly within the housing 1810. The housing also includes a first ridge 1820a and a second ridge 1820b. Each of the ridge 1820a and the ridge 1820b extends from near the first top edge of the housing 1810 to near the opposite second bottom edge of the housing 1810. In use, the arcuate shape of the housing 1810 allows the distance between the external propulsion blades of the screening device and the screening filter element assembly to be substantially consistent, thereby reducing clogging and extending the life of the screen elements.

[0110] Similar to other screening filter element assemblies of the present disclosure, as Figure 18B shown in the top cross-sectional view 1850 of the screening filter element assembly 1800 as shown in Figure 18B , each screen unit 1830 may include two end frame units 1855 and a single inner frame unit 1857, and each of the two end frame units 1855 and the single inner frame unit 1857 has a screen element 1860 attached to the corresponding surface of the frame unit.

[0111] The screen units 1830 may be mechanically joined or otherwise fixed together to form a screen assembly. To this end, in one embodiment, each screen unit 1830 may include one or more fasteners, which may allow or otherwise facilitate fixing the first screen unit in the screen units 1830 to the second screen unit in the screen units 1830. Regardless of the mechanism of the adjacent screen units, the respective screen elements of the screen units 1830 may form the screening surface of the screening filter element assembly 1800. The housing 1810 also includes an opening that allows at least a portion of the screening surface to be exposed, as Figure 18B shown in the side view 1890 of the screening filter element assembly 1800 as shown in Figure 18B .

[0112] As shown in Figure 18B the cross-sectional views 1850 and 1870 as shown in Figure 18B , the housing 1810 may include an attachment frame portion 1852 and a retainer frame portion 1854. The attachment frame portion 1852 and the retainer frame portion 1854 are also shown in the perspective view of the housing 1810 as shown in Figure 19A Figure 19A . The retainer frame portion 1854 may receive and / or hold the screen assembly formed by the screen units 1830. To this end, in some embodiments, the retainer frame portion 1854 includes an opening 1910 and includes side walls 1920, 1930, and an inner side wall of the side wall. In Figure 19A the perspective view of Figure 19A , the other inner side walls are not visible. For example, as shown in Figure 19BAs shown in the cross-sectional view 1950 of the housing 1810, the inner sidewall of the retainer frame portion 1854 further includes a sidewall 1960 opposite to the sidewall 1920 and a sidewall 1980 opposite to the sidewall 1930. The sidewall 1920 connected to the sidewalls 1930 and 1980 may define a first opening, and the opposite sidewall 1960 connected to the sidewalls 1930 and 1980 may define a second opening. The cross-sectional area of the second opening may be larger than that of the first opening to reduce the reduction of the undesired screening area. The smaller cross-section may provide greater mechanical stability for the screen assembly disposed within the housing 1810. The first opening and the second opening may allow particulate matter to flow from the outside of the screening filter element assembly including the housing 1810 to the inside. The particulate matter may be screened or otherwise separated by such a screen assembly. Specifically, the particulate matter may be separated from the slurry outside the screen basket device having a screening filter element assembly including the screen assembly, and may flow into the inner region of the screen basket device as expected or required by screening applications (e.g., CIL process, CIP process, ore processing, water desalination, etc.).

[0113] As further shown in cross-sectional views 1870 and 1970 of Figure 18B and Figure 19B , the retainer frame portion 1854 may include ridges 1872 configured to receive the screen assembly near the opening and a ridge 1874 near the base of the housing 1810.

[0114] Additionally, further referring to Figure 19A , the attachment frame portion 1852 includes inner sidewalls, including sidewall 1946 and sidewall 1948, and other sidewalls opposite thereto respectively. One of such opposite sidewalls may be found in Figure 19B the side view 1990 of Figure 19C . Specifically, the sidewall 1992 is opposite to the sidewall 1946. The attachment frame portion 1852 further includes ridges 1820a and 1820b. In one embodiment, the ridges 1820a and 1820b and the corresponding portions of the attachment frame portion 1852 form corresponding notches 1856. As described above, these notches may allow or otherwise facilitate the installation (e.g., clamping, gripping, or otherwise engaging) of the screening filter element assembly 1800 to the grille frame of the present disclosure, such as the grille frame 1510 disclosed above. As an illustration,

[0115] Figure 20AShows an example of a sieve assembly 2000 in accordance with one or more embodiments of the present disclosure. The exemplary sieve assembly 2000 may be arranged or otherwise assembled within a housing 1810 or any other housing described herein to form a sieve filter element assembly in accordance with the present disclosure. Consistent with other sieve assemblies disclosed herein, the sieve assembly 2000 includes three frame units, which may include two end frame units 1855 and a single inner frame unit 1857, and each of the end frame units 1855 and the inner frame unit 1857 includes a sieve element 1860 fixed thereto. The present disclosure is not limited to three frame units 1855, 1857 and / or a specific number of sieve elements 1860 for each frame unit 1855, 1857. In some embodiments, two sieve elements 1860 may be attached thereto for each of the three frame units 1855, 1857. In some embodiments, fewer or additional frame units 1855, 1857 and / or sieve elements 1860 may be implemented. Each of the frame units 1855, 1857 (or in some embodiments, at least one) may be embodied as a single injection molded piece integrally formed by injection molding of a polymer. The frame units 1855, 1857 may be mechanically connected or fixed together to form the sieve assembly 2000. To this end, in one embodiment, each of the frame units 1855, 1857 may include one or more fasteners that may allow or otherwise facilitate fixing the first of the frame units 1855, 1857 to the second of the frame units 1855, 1857. Regardless of the mechanism utilized or relied upon to connect the frame units, the connected frame units 1855, 1857 form a first segmented edge member and an opposing second segmented edge member (not visible in Figure 20A ). The connected frame units 1855, 1857 also include a first integral edge member and a second integral edge member corresponding to the edge members of the outer frame units 1855, 1857 respectively (not visible in Figure 20A ).

[0116] The sieve elements 1860 fixed to each of the frame units 1855, 1857 may form the screening surface of the sieve assembly 2000 and the sieve filter element assembly including the sieve assembly 2000. The screening surface may be seamless, as shown in cross-sectional views 2050 and 2070 of the sieve assembly 2000 in Figure 20B . In some embodiments, as illustrated in side view 2090 of the sieve assembly 2000 in Figure 20B , each sieve element 1860 (or in other embodiments, at least one) may include four adjacent portions having corresponding sets of sieve holes. Such portions may be separated by support members (represented by dashed lines in plan view 2090). The present disclosure is not limited to sieve elements having four portions, and in some embodiments, fewer or additional portions having sieve holes may be implemented.

[0117] Figure 21A A perspective view of an inner frame unit 1857 according to one or more embodiments of the present disclosure is shown. The inner frame unit 1857 is elongated and includes longitudinal side members 2138 that are opposite each other and generally parallel to each other. The inner frame unit 1857 also includes transverse side members 2136 that are opposite each other and generally parallel. Each of the transverse side members 2136 is generally perpendicular to the longitudinal side members 2138. As described above, the inner frame unit 1857 may include a fastening mechanism that allows or otherwise facilitates mechanically coupling or securing the inner frame unit 1857 and another frame unit (the end frame unit 1855 or the inner frame unit 1857) together. Specifically, in some embodiments, the fastening mechanism may be assembled or otherwise formed on corresponding portions of the longitudinal side members 2138, and the transverse side members 2136 do not have a fastening mechanism. As Figure 21A shown, in at least one of such embodiments, the fastening mechanism may be embodied in or may include clips 2142 and clip holes 2140. The inner frame unit 1857 and another frame unit (e.g., the end frame unit 1855) that also have clips 2142 and clip holes 2140 may be mechanically coupled or secured together along their respective longitudinal side members 2138. To this end, in one embodiment, the clip 2142 of the inner frame unit 1857 may pass through the clip hole 2140 of another frame unit until the extension member of the clip 2142 extends beyond the clip hole 2140 and the longitudinal side member of the other frame unit. As the clip 2142 is pushed into the clip hole 2140, the extension members of the clip 2142 may be forced together until the clamping portions of each extension member extend beyond the longitudinal side member of the other frame unit, thereby allowing the clamping portions to engage the interior of the longitudinal side member of the other frame unit. When the clamping portions are engaged into the clip holes 2140, the longitudinal side members of the two separate frame units may be side-by-side and secured together (e.g., mechanically coupled). The frame units may be separated by applying a force to the extension members of the clip to move the extension members relative to each other to allow the clamping portions to come out of the clip holes 2140. Although the fasteners described herein and shown in the drawings are clips and clip holes, the present disclosure is not limited thereto, and alternative fasteners and alternative forms of clips and / or holes may be used, including other mechanical devices, adhesives, etc.

[0118] The inner frame unit 1857 further includes longitudinal support members 2146 and transverse support members 2148. Each longitudinal support member 2146 is substantially parallel to the longitudinal side member 2138 and substantially perpendicular to the transverse side member 2136. Each transverse support member 2148 is substantially parallel to the transverse side member 2136 and substantially perpendicular to the longitudinal support member 2146. The longitudinal support members 2146 and the transverse support members 2148 at least partially define a plurality of grid openings within the inner frame unit 1857. Additionally, the longitudinal support members 2146 and the transverse support members 2148 can provide mechanical stability for the sieve elements fixed to the inner frame unit 1857.

[0119] The inner frame unit 1857 may further include a second transverse support member 2145 that is substantially perpendicular to the longitudinal side member 2138. As Figure 21A shown in the side view and Figure 21B side view 2170 shown, the second transverse support member 2145 may be distributed over the grid openings in the inner frame unit 1857. The second transverse support member 2145 can provide further mechanical stability for the sieve elements attached to the inner frame unit 1857.

[0120] To allow or otherwise facilitate the fixing of one or more sieve elements to the inner frame unit 1857, attachment members 2144 and a number of bonding arrangements are included in the inner frame unit 1857. As shown in the side view 2190 of the inner frame unit 1857 as shown in Figure 21B , the first bonding arrangement includes a plurality of welding strips 2172 assembled (e.g., formed) on the surface of the longitudinal side member 2138. As shown in the top view 2150 of the inner frame unit 1857 as shown in Figure 21B , the second bonding arrangement includes a plurality of welding strips 2152 assembled (e.g., formed) on the surfaces of the transverse side member 2136 and the transverse support member 2148. As shown in the side view 2170 of the inner frame unit 1857 as shown in Figure 21B , the third bonding arrangement includes a plurality of welding strips 2176. In some embodiments, the height of the welding strips 2176 can be less than the height of the welding strips 2172 and also less than the height of the welding strips 2152.

[0121] In some embodiments, the attachment member 2144 can allow or otherwise facilitate the alignment of the sieve elements for laser welding to the inner frame unit 1857 or another type of frame unit disclosed herein. The attachment member 2144 and / or various welding strips can melt during laser welding.

[0122] The end frame unit 1855 can have a structure similar to that of the inner frame unit 1857. The fixing mechanism in the end frame unit 1855 can be included in a single longitudinal side member of the frame unit 1855.

[0123] In some embodiments, the sieve element may be embodied in or may include the sieve element 1860, as Figure 22A shown. The sieve element 1860 includes a first side portion 2220 and a second side portion 2222 that form a seamless perimeter. The first side portions 2220 are substantially parallel to each other, and each of the first side portions 2220 is substantially perpendicular to the second side portion 2222. Similarly, the second side portions 2222 are substantially parallel to each other, and each of the second side portions 2222 is substantially perpendicular to the first side portion 2220. Each side portion 2220 is configured to rest and be fixed on a lateral side member (e.g., member 2136) of the frame units 1855, 1857 (e.g., the inner frame unit 1857). Thus, each side portion 2220 may include a cavity configured to receive or otherwise engage a weld strip on the surface of the lateral side member. Similarly, according to the present disclosure, the side portion 2222 is configured to rest on a longitudinal side member of the frame units 1855, 1857 (e.g., the frame unit 1857). Accordingly, each of the side portions 2222 includes a cavity configured to receive or otherwise engage a weld strip on the respective surface of the longitudinal side member.

[0124] The sieve element 1860 further includes a plurality of support members. More specifically, the sieve element 1860 includes a support member 2230 and a support member 2238. The support members 2230 are substantially collinear and substantially perpendicular to the support member 2238. The support members 2238 are also substantially collinear. The sieve element 1860 further includes a support member 2240 extending from a first side portion of the side portions 2222 to a second side portion of the second side portions 2222. Each of the support members 2230, 2238, and 2240 is configured to rest or be fixed on a corresponding support member of the frame units 1855, 1857 (e.g., the inner frame unit 1857). Accordingly, each of the support members 2230, 2238, and 2240 includes cavities configured to receive or engage a weld strip on the respective surface of the corresponding support member of the frame unit.

[0125] The sieve element 1860 further includes attachment holes 2224. One of the attachment holes 2224 is substantially located at the center of the sieve element 1860. The other attachment holes 2224 are located at the respective corners of the seamless perimeter of the sieve element 1860. Regardless of the position in the sieve element 1860, each of the attachment holes 2224 (or, in some embodiments, at least one) is configured to allow or otherwise facilitate an elongate attachment member 2144 (e.g., Figure 21A) can pass through the attachment holes 2224. In one or more such embodiments, the attachment holes 2224 may include tapered holes that can be filled when a portion of the elongated attachment member 2144 above the screening surface of the screen element 1860 melts, thereby fastening the screen element 1860 to the inner frame unit 1857 or another type of frame unit disclosed herein. In other embodiments, the attachment holes 2224 may be configured to not have tapered holes, thereby allowing molten beads to form on the screening surface 2013 of the screen element 1860 when a portion of the elongated attachment member 2144 above such screening surface melts, thereby fastening the screen element 1860 to the inner frame unit 1857 or another type of frame unit disclosed herein. The screen element 1860 may cover a half portion of the inner frame unit 1857 (or another type of frame unit disclosed herein), and each of the four portions included in the screen element 1860 may respectively cover four grille openings of the inner frame unit 1857.

[0126] The screening surface 2213 has a plurality of screening holes. Each of the plurality of screening holes (or in some embodiments, at least some) may be elongated and may have a defined length and a defined width having corresponding sizes based on the screening application using the screen element 1860 (e.g., CIL process, CIP process, ore processing, water desalination, etc.). In some embodiments, the plurality of screening holes may have the same substantially uniform length, which length is in the range of about 300 μm to 4000 μm. Additionally, the plurality of screening holes may have the same substantially uniform width, the size of which is in the range of about 35 μm to about 4000 μm. As an example, in some embodiments, the size of the width may be approximately equal to one of 43 μm, 74 μm, 90 μm, 104 μm, 125 μm, 150 μm, 180 μm, 500 μm, 700 μm, or 1000 μm (1 millimeter). In one exemplary embodiment, the plurality of screening holes may have a substantially uniform length, which length is about 500 μm. As Figure 22A and Figure 22B (showing top view and side views 2250, 2270, and 2290 of the screen element 1860), the plurality of opening partition segments can be arranged, and the screening holes in one segment can be arranged in a grid pattern. Each segment is at least partially defined by the support members 2230, 2238, and 2240 of the screen element 1860. In one embodiment, the screening holes adjacent to the periphery of the screen element 1860 can be defined by longitudinal bars parallel to a first side portion of the screen element 1860, transverse bars perpendicular to the longitudinal bars, and segments of the edges of the side portions of the screen element 1860. Additionally, the screening holes inside one segment can be defined by the longitudinal bars and the transverse bars. The longitudinal bars define the main sides of the elongated openings, while the transverse bars define the secondary sides of the elongated openings.

[0127] AsFigure 23A and 23B As shown in Figure 23B , some embodiments may include a fastening mechanism in a frame unit (inner frame unit 2357 or end frame unit 2355), which may allow or otherwise assemble a sieve assembly 2300 having a certain curvature. In one such embodiment, the fastening mechanism may include a clip and a clip hole, such that the assembled sieve assembly 2300 is curved rather than substantially planar, as shown in side views 2350, 2570, and 2390 of the curved sieve assembly 2300 shown in Figure 23B . Figure 23B as shown in side views 2350, 2570, and 2390 of the curved sieve assembly 2300 shown in Figure 23B .

[0128] Figure 24 and Figure 25 An alternative embodiment of the filter element assembly 2400 for the sieve basket of the present disclosure is shown. The filter element assembly 2400 includes a detachable housing having a top shell portion 2410 and a separate bottom shell portion 2411. Both the top shell portion 2410 and the bottom shell portion 2411 include an attachment mechanism 2440 that detachably engages holes 2445 provided on the top shell portion 2410 and the bottom shell portion 2411. In use, a sieve assembly having a sieve unit 2430 can be assembled into the top shell portion 2410 or the bottom shell portion 2411, and then the opposing shell portions can be assembled around the sieve assembly through the sieve unit 2430. The attachment mechanism 2440 engages the holes 2445 to securely fix the sieve assembly and the sieve unit 2430 within the housing.

[0129] The detachable housing having a top shell portion 2410 and a bottom shell portion 2411 includes features substantially the same as the housing 1810 discussed herein, including an attachment frame portion, a retainer frame portion, and ridges. As shown in the perspective view of the bottom shell portion 2411 shown in Figure 25 , the attachment frame portion 2452 includes inner sidewalls and attachment ridges 2420a and 2420b, which allow or otherwise facilitate the installation (e.g., clamping, gripping, or otherwise engaging) of the screening filter element assembly 2410 to a grille frame of the present disclosure, such as the grille frame 1510. The retainer frame portion 2454 may receive and / or retain a sieve assembly formed by a sieve unit in a manner substantially similar to the retainer frame portion 1854 of the housing 1800 discussed in more detail herein. Figure 25 As shown in the perspective view of the bottom shell portion 2411 shown in Figure 25 , the attachment frame portion 2452 includes inner sidewalls and attachment ridges 2420a and 2420b, which allow or otherwise facilitate the installation (e.g., clamping, gripping, or otherwise engaging) of the screening filter element assembly 2410 to a grille frame of the present disclosure, such as the grille frame 1510. The retainer frame portion 2454 may receive and / or retain a sieve assembly formed by a sieve unit in a manner substantially similar to the retainer frame portion 1854 of the housing 1800 discussed in more detail herein.

[0130] The top shell portion 2410 and the bottom shell portion 2411 can each be formed from a single injection molded piece that is integrally formed by injection molding polyurethane, a thermosetting polymer, or other types of polymers. Due to the relative simplicity of the separate top shell portion 2410 and bottom shell portion 2411, as compared to a single housing (such as housing 1810), the top shell portion 2410 and the bottom shell portion 2411 can be more easily formed by an injection molding process. Example embodiments of the injection molding process are discussed in detail in U.S. Patent Application 13 / 800,826, U.S. Patent 9,409,209, U.S. Patent 9,884,344, U.S. Patent Application 15 / 851,009, U.S. Patent Application 15 / 965,195, and the disclosures of the cross-references included therein, which are hereby incorporated by reference in their entirety.

[0131] Although embodiments of the present disclosure have been described with reference to various embodiments and developments, it will be understood that these embodiments are illustrative and that the scope of the embodiments of the present disclosure is not limited to them. Many variations, modifications, additions, and improvements are possible. Accordingly, the above description should not be construed as restrictive, but merely as an example of particular embodiments.

Claims

1. A sieve assembly configured to be disposed within a housing, the housing being attached to a grille frame of a sieve basket device, and the sieve basket device being used for an inter-stage screening process, the sieve assembly comprising: A frame unit configured to be disposed within the housing, the housing being attached to the grille frame of the sieve basket device and covering an opening of the grille frame; And A sieve element including a screening surface attached to the frame unit, the sieve element being formed of a thermoplastic material, wherein sieve holes are formed in the screening surface, the sieve holes being configured to separate carbon or resin particles from a slurry of carbon-in-leach (CIL), carbon-in-pulp (CIP), or resin-in-leach (RIL) during an inter-stage screening process, and the width of the sieve holes ranging between 35 microns and 4000 microns.

2. The sieve assembly according to claim 1, wherein, The width of the sieve holes ranges between 104 microns and 1000 microns.

3. The sieve assembly according to claim 1, wherein the width of the sieve holes ranges between 500 microns and 1000 microns.

4. The sieve assembly according to claim 1, wherein the screening surface is formed of polyurethane.

5. The sieve assembly according to claim 1, wherein the sieve element comprises a single injection molded piece integrally formed by injection molding of a thermoplastic material.

6. The sieve assembly according to claim 1, wherein the sieve holes on the screening surface have substantially the same uniform length and substantially the same uniform width.

7. The sieve assembly according to claim 6, wherein the sieve holes are elongated with a length greater than the width, wherein the length of the sieve holes is between 300 microns and 4000 microns, and wherein the width of the sieve holes is between 35 microns and 4000 microns.

8. The sieve assembly according to claim 1, wherein the open screening area of the screening surface is between 40% and 46% of the total area of the screening surface.

9. The sieve assembly according to claim 1, wherein the housing comprises: An attachment frame portion configured to attach the housing to the grille frame of the sieve basket device; And A retainer frame portion to which the frame unit is mounted.

10. The sieve assembly according to claim 9, wherein the attachment frame portion of the housing includes a first notch and a second notch configured to engage a transverse member of the grille frame of the sieve basket device.

11. The sieve assembly according to claim 9, wherein each retainer frame portion of the housing is configured such that a plurality of frame units and associated attached sieve elements can be mounted to the retainer frame portion.

12. The sieve assembly according to claim 1, wherein the housing has an arcuate shape.

13. The sieve assembly according to claim 1, wherein the housing includes a top housing portion and a bottom housing portion, and each of the top housing portion and the bottom housing portion has an attachment mechanism and a hole, and the attachment mechanism detachably engages with the hole.

14. The sieve assembly according to claim 1, wherein the housing is formed by injection molding of polyurethane or a thermosetting material.

15. The sieve assembly according to claim 1, wherein the frame unit includes a fastening mechanism configured to cooperate with a corresponding fastening mechanism on another frame unit such that the two frame units can be connected together.

16. The sieve assembly according to claim 1, wherein the frame unit includes an attachment member and a welding strip.

17. The sieve assembly according to claim 1, wherein the frame unit includes: a first longitudinal side member and a second longitudinal side member opposite and substantially parallel to the first longitudinal side member; and a first transverse side member and a second transverse side member opposite and substantially parallel to the first longitudinal side member; wherein the first transverse side member is perpendicular to each of the first longitudinal side member and the second longitudinal side member; wherein the second transverse side member is substantially perpendicular to each of the first longitudinal side member and the second longitudinal side member.

18. A sieve element for use in at least one screening process in a carbon-in-leach (CIL), carbon-in-pulp (CIP), or resin-in-leach (RIL) interstage screening process, comprising: a body formed of a thermoplastic material; and a plurality of sieve holes extending through the body, the sieve holes being configured to separate carbon or resin particles from a slurry of carbon-in-leach (CIL), carbon-in-pulp (CIP), or resin-in-leach (RIL) in an interstage screening process, the width of the sieve holes ranging from 35 microns to 4000 microns.

19. The sieve element according to claim 18, wherein the width of the sieve holes ranges from 104 microns to 1000 microns.

20. The sieve element according to claim 18, wherein each of the sieve holes has substantially the same uniform length and substantially the same uniform width.

21. The sieve element according to claim 20, wherein the sieve holes are elongated with a length greater than the width, wherein the length of the sieve holes ranges from 300 microns to 4000 microns, and the width of the sieve holes ranges from 35 microns to 1000 microns.

22. The sieve element according to claim 18, wherein the open screening area of the body is between 40% and 46% of the total area of the body.

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