ENDURON® Elite banana screens

About this product

Often referred to as multi-slope vibrating screens, Weir's range of ENDURON® Elite banana screens for hard rock mining and mineral processing offer exceptionally high throughput per area, delivering significant advantages in efficiency, and lowering total flowsheet energy consumption by up to 40%. Our double-deck banana screens have simplified maintenance requirements, ensuring minimal downtime. Overview ENDURON® Elite double-deck banana screens, often referred to as "multi-slope" vibrating screens, are designed for dry and wet screening applications within mining and mineral processing industries. Weir's ENDURON® vibrating screens are renowned for their performance and high capacity within fine sizing applications. They offer exceptionally high throughput per screening area and are very effective where the minerals to be classified contain a large amount of fine material. Each screen is expertly designed following in-depth material testing and review of the application’s particle size distribution (PSD). All ENDURON® Elite banana screens are engineered for your particular needs, meaning that they fit perfectly and are fully equipped to perform in each specific application. Compared to other vibratory screens, ENDURON® Elite banana screens offer the following benefits: • High tonnage, efficient screening even at smaller cut sizes. • Excellent sizing efficiency due to rapid stratification (sorting according to size) of material. • High specific capacity per unit area, resulting in reduced screen (unit) size. • Simplified maintenance requirements, ensuring minimal downtime. • Improved inventory management by reducing the number of exciters required to drive large vibrating screens. • High acceleration screening to break up agglomerated fines typical of HPGR discharge. • Optimised integration with our ENDURON® HPGR for a more sustainable mining process. • Digitally empowered by NEXT Intelligent Solutions for equipment monitoring and process optimization. For more information about ENDURON® Elite screens, get in touch with our team. Frequently Asked Questions When would I select a banana vibrating screen over a horizontal/inclined screen? There are some applications where neither inclined nor horizontal screens are the best solution. For instance, you may want to combine the high production rate of inclined screens with the sorting efficiency of horizontal screens. ENDURON® Elite banana screens combine these two features and have an aggressive feed slope (between 25-35 degrees). They are, therefore, recommended for applications where the feed contains a large amount of fine material. These vibrating screens ensure that fine material gets a chance to stratify through the material bed to the deck. Compared with a horizontal vibrating screen of equal size, the ENDURON® Elite banana screen can typically carry close to 30% more throughput, depending on the application. Ultimately, this means that in some applications, you achieve the equivalent throughput of a horizontal vibrating screen with a 30% smaller banana screen. These vibratory screens are also ideal when screening ENDURON® HPGR discharge, which is extremely fine. How does a banana vibrating screen work? With banana screening equipment, as the product enters the vibrating screen, high velocity is immediately applied to it. That causes the oversized material to run over the deck quickly, creating inter-particle space in the feed section. This process ensures that the fine material gets a chance to stratify through the material bed to the deck. The fine material is then screened through the apertures. A high percentage of the fine material is screened in the first third of the machine. With the fine material out of the way, the second third of the screen removes the P80, while the final third – where the slope is typically between 5-15 degrees but can be as low as zero degrees – removes the P90 and above. This material is slightly smaller than cut size and, therefore, very difficult to screen. But, with the majority of the material removed in the first two-thirds of the screening process, it becomes much easier. Eventually, you are left with a very thin layer of material that can be screened much more effectively. What are the ETX exciters and why are they an important feature of the ENDURON® ELITE banana screen design? The mining industry is dealing with the challenges of declining ore grades and fewer large mines coming into operations, meaning that existing mines need to process higher tonnages, which, in turn, requires higher screening capacity. This presents some design challenges, and Weir had to develop an exciter capable of driving a screen with a deck that spans 4.27m 8.5m and weighs up to 50 tonnes. This has been a long and rigorous process that involved initially designing a range of exciters, building and testing prototypes and then commercialising a serial production version. What is innovative about the ENDURON® Elite banana screens is that they are driven by two patented ETX exciters, whereas all other machines of comparable size on the market today require three exciters. Weir's ETX exciters feature the largest vibration-duty bearings in the world. There are operational benefits because it means there are fewer exciters to maintain on-site, which reduces downtime, routine inspections and inventory management. In terms of performance, the two exciters on the ENDURON® Elite vibrating screens are mounted closer to the sideplates, which reduces the force acting on the middle of the exciter beam. Moving the exciters closer to the sideplates also reduces the localised bending moment at the beam and sideplate interface. In contrast, vibrating screens with three exciters experience higher levels of deflection in the exciter beam, which results in heavier exciter beam designs. What screen media do you offer for this product? We offer ENDURON® rubber and polyurethane screen media panels to suit a variety of applications. How many G-forces do your screens operate with? Depending on the application, up to 5G unloaded. Can I change the speed of my ENDURON® ELITE banana screen without changing the stroke length? Yes, but it requires adjusting both the motor rotational speed and the out-of-balance weight setting independently. Changing the motor speed is only allowed in a very narrow band, however – considering the natural frequency bands a typical banana vibrating screen operates in. Please consult with your local Weir service representative before making any operational changes to your ENDURON® screening equipment. Why is the oil level important in exciters, gear cases and bearing assemblies? Exciters, gear cases, and bearing assemblies are all rotating mechanical elements, meaning they build up heat quickly. It is critical that they remain well lubricated, especially when it comes to the bearings. How much pressure should be seen at the spray bars? Typically 200 – 300kpa, depending on the application. How much water does it take for wet screening? This varies from application to application. It can be anything from 0.3mr/hr/ton – 1.5mr/hr/ton. What are the advantages of locking bolts? Locking bolts prevent connections from becoming loose under vibration. Why is a flexible motor mount required? A flexible motor mount is required because the screen moves and the electric motor driving the screen is on a static frame. How do I decide on the best screen media for my screen? Choosing the right screening media for your application is critical to the performance of your vibrating screen. Some of the key things to consider include: • The required cut point • The density, abrasiveness and type of ore • Moisture content • Particle shape and size • Percentage of near-size material • Whether it will be wet or dry screening • Required material bed depth, travel rate and deck inclination • Vibrating screen motion (Eg. stroke, throw angle, circular, linear or elliptical) In combination, these factors impact which screen media is best suited. For personalised advice on choosing the right screen media, please contact our team. Alternatively, you can read more about our ENDURON® screen media offering here. Can wet kits be retrofitted to a banana screen? Yes, but there are some limitations. On the lower decks, for example, it can be very difficult given there is usually no pre-drilled spray pipe holes in the sideplates. What additional wear protection is possible? We offer various grades of LINATEX® premium rubber and hard-wearing metal liners to provide additional wear protection. Featuring the latest in screening technology ENDURON® Elite banana screens are supplied featuring our proprietary range of exciters (the largest exciters in the world)! Weir’s ETX exciters are capable of driving a vibrating screen with a deck that spans 4.27m. Vibrating screens of this size typically require three exciters, but this increases the amount of deflection experienced in the exciter beam, resulting in heavy exciter beam designs. Our ETX Exciters have the largest capacity of any exciter currently available on the market, which: • Allows large vibratory screens to be driven with two exciters, reducing exciter drive complexity and maintenance costs. • Provides high performance and long service life. • Reduces downtime, routine inspections and inventory management as there are fewer exciters to maintain on-site. All ENDURON® Elite vibrating screens feature LINATEX® premium rubber, which is installed to protect the vibrating screen in highly corrosive applications and to lower the total cost of ownership. Features and benefits Built to Perform ENDURON® Elite banana screens are built to perform, capable of achieving exceptional throughput per screening area and excellent sizing efficiency due to rapid stratification of the material bed. Our vibrating screens are engineered according to industry-leading high-cycle fatigue design criteria. Our high-performance banana screens also incorporate wear-resistant protection materials to help combat areas of high wear, increasing the overall lifetime of the screen. Designed for Any Challenge At Weir, we have ENDURON® Elite banana screening equipment to suit every kind of challenge. We offer heavy-duty screen configurations with an all-bolted construction (using locking bolts) to ensure structural integrity and deliver high throughput and performance in hard-wearing applications. ENDURON® Elite banana screens are available for both wet and dry screening applications. Part of Weir's Transformational Flowsheet solution With the mining industry increasingly focused on sustainability and Weir’s commitment to helping its customers reduce their energy consumption in the grinding circuit, we have developed our transformational flowsheet solution, which replaces traditional tumbling mills with HPGRs and vertical stirred mills. Weir’s transformational flowsheet features a closed circuit with our ENDURON® HPGR in combination with ENDURON® Elite banana screens. This powerful duo works together delivering efficiency and cost-effectiveness for miners. How it works: • The HPGR discharge is fed to the ENDURON® Elite screen. • Oversized material is recycled back to the HPGR, while undersized is fed to the vertical stirred mill. • Our banana screens separate material at high tonnages and small cut sizes with impressive efficiency. This circuit allows miners to use a single mill flowsheet, dramatically cutting energy consumption and operating costs compared to traditional tumbling mills. Digitally empowered These screens are digitally empowered through NEXT Intelligent Solutions allowing advanced real-time monitoring of equipment, including bearing health, temperature, vibrations, acceleration, throw angle and overall screen health. A Variety of Media Options Available ENDURON® Elite banana screens come with a variety of screen media options including ENDURON® polyurethane modular panels and ENDURON® rubber modular panels. Enhanced safety with static exciter guards ENDURON® Elite banana screens can be supplied with static exciter guards. That eases maintenance interventions by making it easier to access the exciter rotating elements. Safe lifting points for the complete assembly and exciters are clearly marked and have undergone strict design verification. Global Service Network All ENDURON® Elite banana screens are backed by our unrivalled Weir global service centre network. Our team is always here to help, regardless of your location. We can also service machinery on site for added convenience. Why Weir? With over 150 years of engineering expertise and decades of creating innovative designs from the highest quality materials, our range of ENDURON® screening equipment is built for maximum throughput and efficiency. Under the ENDURON® screen range, we offer banana, inclined and horizontal vibrating screens, all designed to meet your specific needs and applications. Our ENDURON® screens are built following a detailed and stringent process to ensure they can handle the tough conditions of mining and minerals processing industries. Our team is always here for you, offering rapid response, high-quality wear parts and local expertise when you need it most, regardless of your location. Applications ENDURON® ELITE banana screens are designed for the dry and wet screening of mineral ores within mining and mineral processing industries. They are suitable for a range of applications, including: Secondary cone crusher screening; tertiary screening; large throughput, fine screening; product screening; feed preparation; and desliming. Most notably, they excel in screening HPGR discharge applications. This application typically requires very large vibrating screens because HPGR circuits operate with up to a 200% recirculation load, resulting in high screen feed rates. Moreover, because the cut size of typical HPGR screens range from 1-4mm, larger screens than those usually employed in typical mining applications are required to ensure optimal performance. In recent years, Weir has been pioneering its transformational flowsheet solutions in which traditional tumbling mills are replaced with ENDURON® HPGRs and vertical stirred mills. This can significantly reduce mines energy consumption and the ENDURON® ELITE screens are a vital element of these flowsheets. Explore our range of ENDURON® HPGR and Screening Solutions. ENDURON® ELITE banana screens are suitable to be used with the following feed materials: • Aluminium • Bauxite / Alumina • Chrome • Coal • Copper • Diamonds • Glass • Gold • Graphite • Iron • Kaolin • Kimberlite • Lead • Limestone • Lithium • Mineral Sands • Molybdenum • Nickel • Oil • Oil Sands • Palladium • Phosphate • Platinum • Potash • Rare Earths • Salt • Silver • Soda Ash • Zinc Processes • Dewatering Screening • Drain and Rinse • Dry Classification • Fine Wet Screening • Fines Removal / Desliming • HPGR Discharge Screening • Secondary Screening • Tertiary Screening • Wet Classification Replacement parts The materials used to manufacture spare and wear parts play a key role in the performance and ultimate success of your ENDURON® ELITE banana screen. Only genuine ENDURON® replacement parts ensure perfect fitment and function when performing maintenance activities on your ENDURON® vibrating screening equipment. We offer a variety of screen media including ENDURON® polyurethane modular panels and ENDURON® rubber modular panels. Our new ENDURON® screen media solutions ENDURON® screen media delivers durable, modular screening solutions designed to maximise uptime, improve screening efficiency and reduce total cost of ownership in mining and minerals processing applications. Available in wear-resistant polyurethane and rubber panels, it supports reliable particle separation across a wide range of duties. Engineered for compatibility with the full ENDURON® vibratory screen range, as well as other vibrating screens, it offers a flexible, high-performance solution backed by Weir’s global expertise and support. Services and maintenance All ENDURON® ELITE banana screens are backed by our unrivalled Weir service centre network. This means that our experts are here to support you, every step of the way, regardless of your site's location. Our expert team will work alongside you to deliver: • High-quality wear and spare parts • Personalised advice and solutions • Servicing of machinery at our service centres or onsite for added convenience • Ongoing support and training Our aftermarket experts work with you to maximise your up-time and can provide comprehensive flowsheets and equipment reviews to ensure you have the correct resources at the right time.