CN113165020A

CN113165020A - Method and device for screening

Info

Publication number: CN113165020A
Application number: CN201980080533.6A
Authority: CN
Inventors: 詹姆斯·R·科尔格罗夫; 克利福德·C·史密斯
Original assignee: Derrick Corp
Current assignee: Derrick Corp
Priority date: 2018-10-04
Filing date: 2019-10-04
Publication date: 2021-07-23
Anticipated expiration: 2039-10-04
Also published as: BR102018075348B1; CL2018003507S1; PE20211622A1; BR102018075348A2; TWM585171U; KR20190003090U; ZA202102970B; JP2022504064A; WO2020072932A2; WO2020072932A3; TWD203476S; CO2021005759A2; DOP2021000057A; CN113165020B; MX2021003922A; JP7432587B2; FI12523U1; AU2019355180A1; EA202190971A1; AU2019355180B2

Abstract

Methods and apparatus for screening are provided. Embodiments include a basket (1) apparatus for screening material that includes a grid frame (1510) having a plurality of openings arranged in a grid and a plurality of screening cartridge assemblies (1610) secured to the grid frame (1510) to cover respective openings of the grid frame (1510). The screen cartridge assembly (1610) includes a housing (1630) and screen assemblies (2000) that fit in the housing (1630) and can be secured to a set of cross members (1512) of a grid frame (1510). The housing (1630) may be a single injection molded piece integrally formed by one of injection molding of polyurethane or thermoset polymer. The screen elements together form a substantially continuous screening surface across the outside of the grid frame (1510), which reduces clogging and is resistant to wear.

Description

Method and device for screening

Cross Reference to Related Applications

This application claims priority from us patent application No. 16/151,909, which is a continuation-in-part application of us patent application No. 16/001,755 filed on 6.6.2018, us patent application No. 16/001,755 claims the benefit of us patent application No. 62/515,964 filed on 6.6.2017 and us patent application No. 62/615,302 filed on 9.1.2018, the contents of which are incorporated herein by reference and claimed priority.

Drawings

Various aspects and features of the disclosure are described herein with reference to the drawings. Like numbers refer to similar, but not necessarily identical, elements throughout.

Fig. 1 illustrates a side view of a screen basket according to an exemplary embodiment of the present disclosure.

Figure 2 illustrates a top view of a screen basket according to an exemplary embodiment of the present disclosure.

Figure 3 illustrates a top side perspective view of a screen basket according to an exemplary embodiment of the present disclosure.

Fig. 4 illustrates a plan view of a polyurethane screen for use with a basket cage according to an exemplary embodiment of the present disclosure.

Fig. 5 illustrates a view of the polyurethane screen of fig. 4 as opposed to the plan view of fig. 4, in accordance with an exemplary embodiment of the present disclosure.

Figure 6 illustrates a side view of a polyurethane screen for use with a basket cage according to an exemplary embodiment of the present disclosure.

Figure 7 is a partial top view showing the attachment of a screening member to a basket frame according to an example embodiment of the present disclosure.

Fig. 8 shows a portion of the polyurethane screen of fig. 4.

Fig. 8A shows a close-up view of the polyurethane screen of fig. 8.

Fig. 9 illustrates a partial side cross-sectional view of a polyurethane screen according to an exemplary embodiment of the present disclosure.

Fig. 9A shows an enlarged view of a partial side sectional view in fig. 9.

FIG. 10 illustrates an enlarged, fragmentary, cross-sectional view taken substantially along line 10-10 of FIG. 9, showing a cross-sectional configuration of a modified shape of the first member with the reinforcing member, according to an exemplary embodiment of the present disclosure.

Fig. 11 illustrates an enlarged, partial cross-sectional view similar to fig. 10, but showing the first member without the reinforcement member, according to an example embodiment of the present disclosure.

Fig. 12 illustrates a partial exploded isometric view of a polyurethane screen having a reinforcement member integral with a first member and a second member according to an exemplary embodiment of the present disclosure.

Fig. 13 shows an exploded view of a screen basket used in an embodiment of a screening device according to an exemplary embodiment of the present disclosure.

Fig. 14 shows a side cross-sectional view of a screen basket used in an embodiment of a screening separator apparatus according to an exemplary embodiment of the present disclosure.

Figure 15 illustrates a perspective view of an exemplary basket according to an exemplary embodiment of the present disclosure.

Fig. 16A illustrates a perspective view of an example screen basket including a plurality of screening cartridge assemblies attached to a basket cage according to an example embodiment of the present disclosure.

Figure 16B illustrates a partial perspective view of the screen basket of figure 16A featuring a plurality of screening cartridge assemblies according to an example embodiment of the present disclosure.

Figure 16C illustrates a partial perspective view of the interior of the screen basket of figure 16A featuring a plurality of screening cartridge assemblies according to an example embodiment of the present disclosure.

Fig. 17 shows a partial cross-sectional view of an exemplary screening cartridge assembly mounted on a grid frame according to an exemplary embodiment of the present disclosure.

Figure 18A illustrates a perspective view of an exemplary screening cartridge assembly according to an exemplary embodiment of the present disclosure.

Figure 18B shows cross-sectional and side views of the exemplary screening cartridge assembly of figure 18A. Example dimensions are shown in inches in the view. The present disclosure is not limited to this size and other sizes are contemplated.

Figure 19A illustrates a perspective view of a housing of an exemplary screening cartridge assembly according to an exemplary embodiment of the present disclosure.

Fig. 19B illustrates a cross-sectional view and a side view of the exemplary housing of fig. 19A. Example dimensions are shown in inches in the view. The present disclosure is not limited to this size and other sizes are contemplated.

Figure 19C illustrates an example of a plurality of shells secured to a grid frame of a basket according to an example embodiment of the present disclosure.

Figure 20A shows an exemplary screen assembly element according to an exemplary embodiment of the present disclosure.

Figure 20B shows a cross-sectional view and a side view of the exemplary screen assembly element of figure 20A. Example dimensions are shown in inches in the view. The present disclosure is not limited to this size and other sizes are contemplated.

Figure 21A shows a perspective view of an exemplary frame unit of a screen assembly according to an exemplary embodiment of the present disclosure.

Fig. 21B shows top and side views of the exemplary frame cell of fig. 20A.

Figure 22A shows an example screening element of a screening assembly according to an example embodiment of the present disclosure.

Figure 22B shows top and side views of the exemplary screening element of figure 22A.

Figure 22C is an enlarged top plan view of a portion of a screening element according to an example embodiment of the present disclosure.

Figure 23A shows another example of a screen assembly element according to an exemplary embodiment of the present disclosure.

Figure 23B shows a side view of the exemplary screen assembly of figure 23A.

Figure 24 illustrates an example of a filter cartridge screening element according to an example embodiment of the present disclosure.

Figure 25 shows an example of a bottom housing portion of the filter cartridge screening element of figure 25.

Detailed Description

The present disclosure relates to apparatus and methods for filtration, and in particular to an improved screen basket for use in a method and system for adsorbing metal from metal-containing ore. Embodiments of the present disclosure may be used with carbon in slurry (CIP), carbon leach (CIL) systems, and resin leach (RIL) systems. For example, CIL and CIP systems are two counter-current methods for adsorbing leached gold in a slurry stream onto activated carbon. In such CIL and CIP processes, a plurality of adsorption tanks are placed in series. The flow of pulp material continues from the first tank to the last tank in the series. At the same time, carbon is counter-currently pumped from the last tank in the series to the first tank. CIP and CIP processes differ in the degree of gold leaching prior to carbon adsorption. For example, in a CIL operation, carbon is added to a leaching tank, and leaching reactions and adsorption occur simultaneously. In contrast, in a CIP process, most of the leachable gold is leached before the first adsorption stage.

A description of a general method for recovering gold from gold-bearing ores using a combination of cyanidation and adsorption processes can be found in us 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 may be equally applied to processes for recovering silver, iron, nickel, and other metals from suitable ores. It is within the scope of the present disclosure to recover any metal from the mined ore.

A description of existing metal screen baskets and their method of use in the CIP process described above can be found in U.S. patent No. 5,238,117. The method described in us patent No. 5,238,117 is commonly referred to in the art as "NKM" vertical sweep interstage screening process, and the screen basket used therein is commonly referred to in the art as NKM screen basket. Typically, such NKM screen baskets comprise a metal support frame provided with a wedge-shaped wide screen wrapped around its peripheral side wall. Wedge wire screens are used to filter materials from metal-rich slurries. The screen basket is attached to the NKM screening apparatus and the lower portion of the NKM screening apparatus, including the attached NKM screen basket, is submerged in a tank containing Carbon In Pulp (CIP) material. Impellers on the NKM screening device cause 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 wedge wire screens is very small, resulting in poor screening efficiency. Low open screen area can also lead to plugging. Plugging in turn forces increased slurry flow through the unplugged areas of the wedge wire screen, which increases the wear rate of the screen. In addition, the individual wires forming the wedge wire screen may degrade or break over time due to forces encountered during the screening process, such as the sweep of the inner and outer pusher blades.

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

The polyurethane screen sidewall may be formed from a plurality of individual polyurethane screen members. These individual polyurethane screen members may be aligned adjacent to one another to provide a substantially continuous screening area through the screen sidewall. In one example, the plurality of individual polyurethane screening elements may include eight individual polyurethane screening elements. In such an embodiment, the eight separate polyurethane screening elements may be arranged such that four of the screening elements are on the lower half of the support frame and four of the screening elements are on the upper half of the support frame.

In certain embodiments, the substantially closed bottom may be provided with a central aperture that allows receipt of a drive shaft of the NKM device.

In certain embodiments, a high open face accumulation urethane screen member comprises: a flexible molded polyurethane body; a screening opening in the body; a set of first substantially parallel flexible members defining opposite first sides of the screening opening; a set of second substantially parallel flexible members defining second opposite sides of the screening opening, whereby the second members are substantially perpendicular to the second members; a set of third substantially parallel members having a plurality of first members therebetween; a set of fourth substantially parallel members having a plurality of second members therebetween; substantially parallel side edge portions on opposite sides of the body, between which a third member extends; a fourth member extends between the first and second ends at opposite ends of the body substantially parallel to the edge portions. The screening openings in the flexible molded polyurethane body of the polyurethane screening member may be about 0.044mm to about 4.000mm between the inner surfaces of the first member and about 0.044mm to about 60.000mm between the inner surfaces of the second member.

The polyurethane screen member may also include a reinforcement member integrally molded in at least one of the first member and the third member and at least one of the second member and the fourth member. In some embodiments, the reinforcing member integrally formed in the first member may have a substantially uniform thickness in the range of about 0.006 inches to about 0.015 inches. The reinforcing member integrally molded with the second member may have a substantially uniform thickness in the range of about 0.015 inches to about 0.040 inches. The reinforcing member may be embodied, for example, as a rod that may be integrally molded with the member. The reinforcing member may also be embodied, for example, as an aramid fiber that is at least one of twisted and braided multistrand fiber having a linear density of about 55 denier to about 2840 denier.

Side edge portions of the polyurethane screening element may be configured for attaching the screening element to a support frame. A plurality of enlarged polyurethane ribs may be integrally formed on the outer surface of the polyurethane screen body and the ribs are disposed substantially perpendicular relative to the sidewall support portion. Each rib of the plurality of ribs may extend substantially from the top to the bottom of the polyurethane screening element.

In other embodiments of the present disclosure, a basket may be provided that includes a tubular or substantially cylindrical grid frame having a plurality of openings. The plurality of openings in the grid frame may be arranged in a square lattice, and each opening (or in some embodiments, at least some) of the plurality of openings may have a square shape. In an example embodiment, the plurality of openings may include 264 square openings. A subset of the plurality of openings may be defined by the longitudinal members and the transverse members. A second subset of the plurality of openings may be defined by the longitudinal members and the lateral segments of the first annular portion of the grid frame, and similarly, a third subset of the plurality of openings may be defined by the longitudinal members and the lateral segments of the second annular portion of the grid frame.

The basket cage may have flanges at the top and bottom of the basket. The top flange and opening may allow or otherwise facilitate mounting of a plate or another type of cover on the flange. Additionally or in other embodiments, the flanges and openings may allow or otherwise facilitate mounting of the basket cage into a sieving separator (e.g., NKM vertically swept interstage devices).

The basket may be used in a separation process to separate particular particulate matter from a slurry or another type of fluid source. To this end, in one embodiment, a screen cartridge assembly may be mounted to the basket cage, which may allow or otherwise facilitate the separation of particular particulate matter from the slurry. Each of the screening cartridge assemblies can be mounted or otherwise secured to a respective set of grid members that at least partially define a respective opening of the grid frame. For openings in rows around the longitudinal axis of the grid frame, one set of grid members supporting a first screening filter element assembly may have common grid members with another set of grid members supporting a second screening filter element assembly.

In some embodiments, each of the plurality of screen cartridge assemblies mounted or secured to the grid frame includes a screen assembly and a housing (or another type of container) configured to receive and retain the screen assembly. In some embodiments, the housing may be implemented as a single injection molded piece integrally formed by injection molding of polyurethane, thermoset polymer, or other types of polymers. Exemplary embodiments of injection molded articles and methods of forming injection molded articles are discussed in more detail in U.S. patent application No. 13/800,826, U.S. patent No. 9,409,209, U.S. patent No. 9,884,344, U.S. patent application No. 15/851,009, U.S. patent application No. 15/965,195, and cross-references contained therein, which are hereby incorporated by reference in their entirety.

In some embodiments, the screen assembly has three separate screen units. The housing includes a first opening configured to receive and/or fit the screen assembly within the housing and a second opening allowing the screening surface of the screen assembly to be exposed to the exterior of the grid frame. The housing also includes a ridge extending from a first edge of the housing proximate the first opening to an opposite second edge of the housing. The ridges and corresponding portions of the housing form respective notches that allow or otherwise facilitate mounting (e.g., grasping or clamping) the housing to the grid frame.

In operation of the separation process, all or substantially all of the grid framework of the screen basket may be covered by the screen assemblies. Thus, in an example embodiment, 264 screening cartridge assemblies may be mounted to corresponding 264 square openings in the grid frame.

Further, the housing may include an attachment frame portion and a retainer frame portion. The retainer frame portion may house and/or retain screen assemblies formed by the screen units. The attachment frame portion may include a set of ridges that form respective notches that, in turn, allow or otherwise facilitate (e.g., by clamping, grasping, or otherwise engaging) attachment of the screening cartridge assembly to the grid frame.

A screening cartridge according to the present disclosure may be any suitable shape for attachment to a grid frame of a basket cage. For example, but not limiting of, the screening cartridge may be square, rectangular, or oval or any other shape. While example embodiments may provide a screening cartridge shaped to substantially match the grid openings of the grid frame (i.e., a square screen cylinder on a grid frame having square grid openings), different shaped screening cartridges may be secured to different shaped grid openings. Similarly, the grid framework of the basket cage may have any suitable shape for screening.

The screen elements and screen cartridges according to the embodiments discussed herein are more resistant to wear, abrasion, bending and chemical corrosion than metal and therefore have a longer life in the CIL process than wedge wire frames. The screening elements discussed herein also allow significantly smaller screening openings to be formed as compared to conventional wedge wire frames, which in turn increases screening efficiency. The use of the screen members described herein provides a significantly larger screening area and significantly reduces blindness compared to conventional wedge wire screen baskets. In use, the screen elements and screen cartridges described herein also allow the distance between the outer pusher vanes of the screening apparatus and the screen cartridge assembly to be substantially uniform, thereby reducing clogging and extending the life of the screen elements.

Referring now to the embodiment shown in fig. 1-5, the screen basket 1 of the present disclosure includes a basket structure 510 having a high open area polyurethane screen 600 attached to the basket structure 510.

As shown in FIG. 1, the rim 510 has a generally cylindrical configuration, although other shapes may be used. The rim 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 vertical support portions extending between the upper end 511 and the lower end 515 of the frame 510. As shown in fig. 2, the vertical support portion of the frame 510 has an inner side 521 and an outer side 522.

As shown in fig. 3, the support for the rim 510 may be formed by a plurality of vertical support members 530 and a plurality of horizontal support members 550. The embodiment shown in fig. 3 includes four primary support members 531 spaced apart along the periphery of the frame 510, and a plurality of secondary support members 542 spaced apart between the primary support members 531. The primary and

secondary support members

531, 542 together connect the upper and lower ends 51, 515 of the frame 510 in a spaced apart arrangement. The horizontal support members 550 may be provided by a plurality of annular rings or curved portions that are joined end-to-end to form a plurality of annular rings in spaced relation throughout the rim 510.

As shown in fig. 3, each vertical support member 531 may include an inner strut portion 532. The inner post portion 532 may, in turn, include a hole 534 therethrough. Horizontal support members 550 pass through apertures 534, securing horizontal support members 550 in a stacked and spaced apart arrangement.

As shown in the top view of fig. 2, the upper end 511 of the frame 510 is provided with an opening to allow for receiving and processing of material within the screen basket 1. The lower end 515 of the frame 510 is provided with a substantially solid or closed bottom 516 for retaining material in the screen basket 1 during processing. The substantially closed bottom 516 may be provided with a central hole 517 for operational arrangement with a shaft of a processing device, as discussed in more detail below.

Embodiments of the present disclosure may include a high open area polyurethane screen 600 attached to the periphery of frame 510, forming a screen basket 1 with an open top, a substantially solid or closed bottom 516, and polyurethane screen side walls 601.

Due to potential size limitations during molding of polyurethane screen 600, polyurethane screen 600 may be provided in the form of individual smaller screening elements 10. For example, as in the embodiment shown in fig. 1, a polyurethane screen 600 may have a plurality of separate screening elements 10. Each screen member 10 is attached to a vertical support of the frame 510.

Fig. 4-6 illustrate features of an example embodiment of a screen member 10 configured to form a polyurethane screen sidewall 601 of a screen basket 1. Figures 4 to 5 show the outer side and the inner side, respectively, of an embodiment of the screening element 10. And figure 6 shows a side view of an embodiment of the screening element 10. The screening elements 10 may include polyurethane screens described in more detail in the following patents and patent publications, which have a common assignee with the present disclosure and are incorporated herein by reference: united states patent No. 8,584,866, united states patent No. 9,010,539, united states patent No. 9,375,756, united states patent No. 9,403,192, united states patent application publication No. 2015/0197827a1, and united states patent application publication No. 2016/0303611a 1.

Referring to fig. 4-7, embodiments of the present disclosure may provide a screening element 10 having a body 12 made of molded polyurethane with unperforated

side edge portions

14, 16. The

side edge portions

14, 16 may each have an integral side ridge portion 29 for sealing adjacent screening elements 10 to each other and for securing the screening elements 10 to the basket 510, as shown in figure 7. Each

side edge portion

14, 16 may include a cast structural member for reinforcing the side ridge portion 29. The

side edge portions

14, 16 may also be formed as members without a cast structure or may include other structural members. The side spine portion 29 may have any suitable shape for attachment to the rim 510. In an exemplary embodiment, the side ridge portions 29 may comprise a shaped member, such as a metal member bent into a desired shape, e.g., a U-shaped member, an L-shaped member, a C-shaped member, or the like. The forming member may be attached to the polyurethane body by heating, pressing, mechanical, chemical, molding, and/or any other suitable method or arrangement.

The body 12 of the screening element 10 also comprises 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 screening element 10. In some embodiments, the side ridge portion 29 may extend the entire length between the upper edge portion 20 and the lower edge portion 18.

The body 12 also includes an outer surface 22 and an inner surface 24. Figure 4 depicts the outer surface 22 of the body 12 when the screening element 10 is secured to the basket 510, for example, as shown in figure 1. Figure 5 depicts the inner surface 24 of the body 12 when the screening element is secured to a basket 510 such as shown in figure 1. The body 12 comprises a first member 101 and a second member 102 forming the screening opening 26, as shown in detail in fig. 8 and 8A. In some embodiments, first member 101 and second member 102 may be configured to include a reinforcement member 50, discussed in more detail below. As shown in the side view of fig. 6, the screen element 10 may also comprise vertical ribs 28 on the outer surface 22 of the screen element 10. However, in certain embodiments of the present disclosure, the screen element 10 may not include the vertical ribs 28.

The body 12 may further include a third member 203 and a fourth member 204. The third and

fourth members

203, 204, and the vertical ribs 28, if present, may also include reinforcing members 50, which will be discussed in more detail below. However, in certain embodiments of the present disclosure, third member 203, fourth member 204, and vertical ribs 28 may not include reinforcing member 50. The third member 203 and the fourth member 204 are generally configured to provide support to the screening openings 26 formed by the first member 101 and the second member 102.

Fig. 8 shows a part of an embodiment of a screening element 10, fig. 8A depicts an enlargement of a part of fig. 8. As shown in the detail view of fig. 8A, the first member 101 and the second member 102 form a first integrally molded grid structure 100 defining the screening opening 26. The third and

fourth members

203, 204 may form a second integrally molded grid structure 200, and the fifth and

sixth members

305, 306 may correspondingly form a third integrally molded grid structure 300.

The reinforcement members 50 may be incorporated into the desired members of the screening element 10. The reinforcement members 50 provide stability to the screen element 10 by preventing the side edges 14, 16 from deforming and/or forming an hourglass (hour-glass). In an exemplary embodiment, the stiffening member 50 may be integrated with the appropriate member (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 reinforcement member 50 may be implemented as a rod integrally molded with the screening element. The reinforcement member 50 may also be embodied as aramid fibers that are at least one of twisted and braided strands such that the fibers act as a core to absorb the polyurethane molded therearound, thereby providing a strong bond therewith. The linear density of the twisted or braided multistrand fiber may be about 55 denier to about 2840 denier, and may preferably be about 15 denier00 denier. When aramid fiber is used in embodiments of the present disclosure, it may be under the trademark aramid

A group of aramid fibers available from dupont. The reinforcing member 50 may also be at least one commercially available aramid fiber available under the trade names TWARON, SULFRON, TEUINCONEX, and TECHNORA from Teijin. The flexibility of the aramid fibers provides a flexible reinforcing system to the molded polyurethane that is able to recover its original molded shape after necessary bending and flexing during handling and installation. In certain embodiments, the reinforcement member 50 may be tensioned prior to molding the polyurethane therearound.

Referring again to the exemplary embodiment shown in fig. 1-4, and the detail view shown in fig. 8, the

grid structures

200 and 300 include bi-directional integrally molded members that form support grids within the members. Due to the nature of the reinforcement members 50 and the configuration of the bi-directional grid structure, the members may have relatively small dimensions and thus provide increased open screening area. The grid structure provides screening strength and support to the openings 26 during vibratory loading and significantly increases the open screening area.

As shown in the detail view of fig. 8A, the first member 101 may extend laterally between the

side edge portions

14, 16 in a substantially parallel manner to each other. The second members 102 may extend laterally between the lower edge portion 18 and the upper edge portion 20 in a manner substantially parallel to each other and substantially perpendicular to the first members 101. In certain embodiments, the thickness of the second member 102 may be greater than the thickness of the first member 101 to provide additional structural support to the screening opening 26.

As described above, and as shown in the exploded isometric view of fig. 12, the first member 101 and/or the second member 102 may include the reinforcement member 50, and may or may not be supported by additional support members or support grid structures. For example, as shown in fig. 9, which depicts a partial cross-sectional view of the body 12 of the screen member 10, the body 12 has a first member 101 and a second member 102, and the bi-directional reinforcement member 50 is integrally formed with the first member 101 and the second member 102. The thickness of the stiffening member 50 integrally molded with the first member 101 is in the range of about 0.006 inches to about 0.015 inches. The thickness of the reinforcement member 50, which is integrally formed with the second member 102 (not shown), is in the range of about 0.015 inch to about 0.040 inch. Such an arrangement may be beneficial for screening applications requiring larger screening openings.

Embodiments of the present disclosure may incorporate the reinforcing member 50 in any of the first, second, third and

fourth members

101, 102, 203, 204 and the rib 28, and may incorporate all or part of the first, second, third and

fourth members

101, 102, 203, 204 and the rib member 28.

As shown in the detail of fig. 8 and 8A, the screening opening 26 may be elongated, with a length dimension between its sides and ends being greater than a width dimension. The width of the screening opening 26, which is the dimension between the inner surfaces of adjacent first members 101, may be about 0.044mm to about 4.0 mm. The length of the screening openings 26, which is the dimension between the inner surfaces of adjacent second members 102, may be about 0.44mm to about 60 mm. The screening openings 26 may additionally have various different shapes. For example, the screening openings 26 may have a rectangular, square, or oval shape, or any other shape that may be formed by the first member 101 and the second member 102. The overall size of the screen element 10 may be about 1.2 meters by 1.6 meters, or may have any other desired size. It is understood that all dimensions set forth herein are exemplary only and not limiting.

Referring briefly to fig. 10 and 11, screening opening 26 may diverge downwardly between outer surface 22 and inner surface 24, wherein first member 101 is substantially in the shape of an inverted trapezoid. This generally trapezoidal shape of the first member 101 prevents clogging in the screen element 10 and the entire polyurethane screen 600. First member 101 may include a reinforcing member 50 integrally molded with first member 101, as shown in fig. 10, or may not include a reinforcing member 50 integrally molded therewith, as shown in fig. 11.

As shown in the detail view of fig. 8A, the thickness of the third member 203 and the fourth member 204 may be greater than the thickness of the first member 101 and the second member 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. As shown in the exemplary embodiment of fig. 8 and 8A, the third members 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 members 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 molded with the third member 203 and the fourth member 204. The third member 203 and the fourth member 204 may be configured to have a minimum thickness by including the reinforcement member 50 while maintaining the necessary structural support for the screening openings 26 formed by the first member 101 and the second member 102 during vibratory screening applications. The bi-directional support system provided by third member 203 and fourth member 204 and the additional support of reinforcement member 50 integrated therein, if included, substantially reduces the thickness of the support member and provides increased open screening area and overall screening efficiency.

The body 12 may further include a plurality of vertical ribs 28. In the embodiment shown in fig. 4 to 6, a series of nine ribs 28 may be provided. The rib 28 may have a thickness greater than the thickness of the third and

fourth members

203, 204 and may have a portion extending away from the inner surface 24 of the body 12. As shown in fig. 2, ribs 28 may also be provided, the ribs 28 extending away from the outer surface 522 of the body 12 and thus providing vertical support along the outer screening side wall 601. The greater thickness and positioning of the ribs 28 provides additional structural support to the first and

second members

10, 102.

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 additionally or alternatively extend transversely 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 reinforcement members 50 integrally molded therein. The ribs 28 may provide additional support to the screening openings 26 and may be configured to have a minimum thickness by including the reinforcement members 50 while providing the necessary structural support to retain the screening openings 26 during vibratory screening applications. Like the third member 203 and the fourth member 204, the support system provided with ribs 28 greatly reduces the thickness of the support member and provides increased open screening area and overall screening efficiency.

Various configurations of reinforcement members 50 may be provided in the support rib members 28 to increase the stability of the screening element 10. The reinforcing members 50 provided in the support rib members 28 may be aramid fibers (or monofilaments thereof), naturally occurring fibers, or other materials having relatively high tensile strength and relatively small cross-sectional area.

Each screen element 10 capable of incorporating such reinforcement members 50 may comprise zero, one or more reinforcement members 50 and the reinforcement members 50 used therein may be of different sizes and materials. The reinforcement 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 screening element 10, as the upper surface of the screen may wear.

The support frame, including the reinforcement members 50 and the bidirectional support members, allows the first member 101 and the second member 102 to be relatively thin, thereby creating a larger screening opening. The embodiments described herein have a relatively large tensile strength and a relatively small cross-sectional area. The manufacturing of the support members and the thin first members 101 results in a larger percentage of open area of the screening elements 10 and the whole screen 600, which in turn increases the capacity of the system. According to embodiments described herein, the open screening area may be in the range of, for example, about 40% to about 46% of the screen.

In accordance with an embodiment of the present disclosure, shaker screen 10 includes a flexible molded polyurethane body 12 having substantially parallel

side edge portions

14, 16 at opposite ends of body 12 and a lower edge portion 18 substantially perpendicular to

side edge portions

14, 16, and an upper edge portion 20 substantially perpendicular to

side edge portions

14, 16 and opposite lower edge portion 18. The polyurethane body 12 also includes an outer surface 22 and an inner surface 24. The first member 101 and the second member 102 are provided to form the screening opening 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 a third member 203 and a fourth member 204, the third member 203 and the fourth member 204 having a thickness greater than the thickness of the first member 101 and the second member 102. The third members 203 extend substantially parallel to each other and transversely between the

side edge portions

14, 16 and have a plurality of first members 101 therebetween. The fourth members 204 extend substantially parallel to each other and laterally between the lower edge portion 18 and the upper edge portion 20, and have a plurality of second members 102 therebetween. The reinforcement member 50 may be integrally molded with the third member 203 and/or the fourth member 204, and additionally, the reinforcement member or rod may be integrally molded with the fourth member 204. The body 12 also includes ribs 28. The ribs 28 may be substantially parallel to each other and extend transversely between the

side edge portions

14, 16. The ribs 28 may also be substantially parallel to each other and extend laterally between the lower edge portion 18 and the upper edge portion 20. The rib 28 has a thickness greater than the thickness of the third member 203 and the fourth member 204, and may include a reinforcing member 50 integrally molded therewith. The body 12 may additionally have a fifth member 305 and a sixth member 306. The fifth members 305 extend substantially parallel to each other and transversely between the

side edge portions

14, 16 and have a plurality of third members 203 therebetween. The sixth members 306 extend substantially parallel to each other and laterally between the lower edge portion 18 and the upper edge portion 20 with a plurality of fourth members 204 therebetween. The reinforcing member 50 may be integrally molded with the fifth member 305 and/or the sixth member 306, and in addition, a reinforcing member or rod may be integrally molded with the sixth member 306.

The screen member according to this embodiment may have an open screening area of greater than 40% and a mesh size ranging from about 0.375 mesh to about 400 mesh. For example, the tested sieves having the above-described configuration include 43 mesh sieves, 140 mesh sieves, and 210 mesh sieves. Each of these screens has an open screening area of about 40% to 46%. Such a large screening area for such relatively fine mesh sizes is achieved by the relatively strong and thin grid framework created by the third, fourth, fifth and

sixth members

203, 204, 305, 306 and the reinforcement members integrally molded therewith.

In the foregoing embodiments and examples, the size of each grid cell formed by the intersection of the third member 203 and the fourth member 204 is approximately 1 inch by 1 inch. Typically, the grid unit may be larger for screens with larger screening openings and smaller for screens with smaller screening openings. This principle is generally applicable to each of the example embodiments discussed herein. The grid unit may also have a substantially rectangular shape or may have any other suitable shape for supporting the screening openings.

The use of the polyurethane screening elements 10 described herein to form the screening side walls 601 on the basket has significant advantages over conventional wedge wire screens. The polyurethane screening elements 10 described herein have better wear, scuff, bend and chemical resistance than metal and therefore have a longer life than wedge wire frames in the CIL process. The polyurethane also allows significantly smaller screening openings to be formed compared to conventional wedge wire frames, thereby improving screening efficiency. The use of the polyurethane screening elements 10 described herein provides significantly greater screening area and significantly reduced clogging compared to conventional wedge wire mesh screen baskets.

In operation, the screen basket 1 described herein may be used with known CIP and CIL apparatus and methods, such as those described in U.S. patent No. 5,238,117. For example, as shown in fig. 13-14, the screen basket 1 is mounted below the volute portion of the NKM vertical swept interstage device. The drive shaft of the NKM device passes from the top through the bottom of the basket 1 and through the central hole of the closed bottom of the basket 1. The gearbox and motor are located above the volute to power the drive shaft. A washing interface is positioned above the polyurethane screen and volute interface to receive the discharged slurry stream.

With the screen basket 1 attached to the NKM device, the lower part of the NKM device, including the screen basket 1, is inserted and hung on a large adsorption tank containing the pulp to be treated. The pulp level in the tank is higher than the liquid level in the screen basket 1. This arrangement causes the pulp to naturally flow through the screens of the screen basket 1 in an effort to equalize the liquid levels in the pulp tank and the screen basket 1. Vanes on the exterior of the NKM unit rotate within the water box around the periphery of the screening side walls of the screen basket 1. The outer blades also help prevent particles from clogging the exterior of the polyurethane screen, for example by carbon and slurry clogging. The pulsing and sweeping action reduces the possibility of carbon and near standard size materials covering the screening openings. Impeller blades located inside the screen, such as on the drive shaft, are used to keep the particles in suspension and to drive the slurry upward toward the volute and wash tank.

During this process the pulp flows upwards through the inside of the screen basket 1. The carbon remains in the sieve. The slurry is present through a washing interface located above the polyurethane screen and volute interface.

In these processes, it can be seen that the continuous rotation of the inner and outer blades near the polyurethane screen, and the flow of a large amount of slurry through the openings of the polyurethane screen, cause severe wear of the screen. The polyurethane screen and basket arrangement described herein is designed to withstand significant wear and is significantly superior to existing wire baskets in CIP and CIL processes.

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

Fig. 15 illustrates a perspective view of an example of a basket 1500 according to another embodiment of the present disclosure. The basket 1500 includes a grill frame 1510 that is tubular (or has substantially cylindrical symmetry) with respect to a longitudinal axis and has a plurality of openings 1513. As such, the grill frame 1510 has a height and a diameter. Illustratively, the height may range in size from about 23 inches (about 58 cm) to about 122 inches (about 310 cm). As another illustration, the diameter may range in size from about 10 inches (about 25.4cm) to about 73 inches (about 185.4 cm). In an exemplary embodiment, the height is about 80 inches (about 203.2cm) in size and the diameter is about 50 inches (about 127cm) in size. It is noted that the present disclosure is not limited to such illustrative sizes of heights and/or diameters, and other dimensions of the grid frame 1510 are contemplated. Additionally, the grid frame 1510 is not limited to being tubular or cylindrically symmetric, but may be configured in any shape suitable for sieving, particularly suitable for carbon retention sieving as discussed herein. The grill frame 1510 may also be formed of any material that provides sufficient structure for the screening process and sufficient support for the screening cartridge to be attached to the grill frame 1510. For example, the grill frame 1510 may be formed of a metal or metal alloy (e.g., stainless steel) or may be formed of a thermoplastic material sufficient to support the screening cartridge. In embodiments featuring a thermoplastic grill frame 1510, the grill frame 1510 may comprise a single injection molded piece. In other embodiments, the grill frame 1510 may be formed of separable pieces that are connected together to form the grill frame 1510.

In certain embodiments, the grid frame 1510 can be formed into a desired shape by bending the perforated sheet material onto itself about a longitudinal axis and engaging opposing edges of the perforated sheet material. The joined opposing edges may form a longitudinal seam 1515. In some embodiments, the perforated sheet of material may be formed of a metal or metal alloy (e.g., stainless steel), and the opposing edges may be joined by welding. In other embodiments, the perforated sheet material may be formed of a rigid plastic and the opposing edges may be joined by laser welding and/or bonding with a suitable adhesive. The plurality of openings 1513 in the grill frame 1510 can be arranged in a square lattice, and each opening (or in some embodiments, at least some) of the plurality of openings 1513 can have a square shape. The plurality of openings 1513 may have other shapes than square, such as rectangular, oval, circular, and the like. Further, the plurality of openings 1513 need not be uniformly shaped throughout the grille frame 1510. For example, some embodiments may feature an optional rectangular opening of varying sizes to form the entire grid frame 1510. In an example embodiment, the plurality of openings 1513 may include 264 square openings. A subset of the plurality of openings may be defined by the longitudinal members 1511 and the transverse members 1512. The openings in such a subset may be referred to as interior openings. A second subset of the plurality of openings can be defined by the longitudinal members 1511 and the lateral segments of the first annular portion 1512a of the grid frame 1510. Similarly, a third subset of the plurality of openings can be defined by the longitudinal members 1511 and the lateral segments of the second annular portion 15l2b of the grid frame 1510. The second and third subsets of openings may be referred to as outer openings.

The first and second

annular portions

1512a, 1512b may be implemented along a longitudinal axis or otherwise constitute respective opposite ends of the grid frame 1510. The flange 1520 may be fixed or otherwise attached to an end of the first annular portion 1512 a. The flange 1520 may include a plurality of first openings 1525. The flange 1520 and the first opening 1525 may allow or otherwise facilitate mounting of a plate or another type of cover on the flange 1520. Additionally or in other embodiments, the flange 1520 and the first opening 1525 may allow or otherwise facilitate installation of the basket cage 1500 into a screen separator apparatus (e.g., a NKM vertical sweep interstage apparatus as shown in fig. 13 and 14). Additionally, second flange 1530 may be fixed or otherwise attached to second annular portion 1512 b. The second flange 1530 may include a plurality of second openings 1535. The flange 1530 and the second opening 1535 may allow or otherwise facilitate installation of the basket cage 1500 into a screen separator apparatus (e.g., an NKM vertically swept interstage apparatus as shown in fig. 13 and 14), and/or securing a wiper assembly of a screen separator (not shown).

Referring to fig. 15, the basket cage 1500 may also include an opening near the second end of the grill frame 1510 near the second flange 1530. The conduit member 1540 may be assembled in the vicinity of the opening. The openings and tubes 1540 may form an outlet that may allow or otherwise facilitate slurry flow from the interior of basket cage 1500 when it is desired to drain the slurry during disassembly.

Similar to other screen baskets of the present disclosure, basket cage 1500 in combination with a screening element may be used to separate particular particulate matter from a slurry or another type of liquid source during a separation process. To this end, in one embodiment, the screening filter element assembly may be mounted to the basket 1500 where it may allow or otherwise facilitate the separation of particular particulate matter from the slurry. Specifically, by way of illustration, fig. 16A shows a perspective view of an example of a screen basket 1600 that includes a plurality of screening cartridge assemblies 1610, according to one or more embodiments of the present disclosure. The plurality of screen cartridge assemblies includes a first screen cartridge assembly 16l0a, a second screen cartridge assembly 1610b and a third screen cartridge assembly 1610 c. Each of the

screening cartridge assemblies

1610a, 1610b, 1610c can be mounted or otherwise secured to a respective set of grid members that at least partially define a respective opening of the grid frame 1510. The screen cartridge assembly 1610 may be removable such that the screen cartridge assembly may be installed onto the basket cage 1500 and then easily removed from the basket cage 1500 for maintenance or repair, or may be permanently affixed to the basket cage 1500. One set of grid members supporting a first one of the screening cartridge assemblies 1610a and 16010b may have a common grid member with another set of grid members supporting a second one of the screening cartridge assemblies 1610a and 16010b for a continuous opening about the longitudinal axis of the grid frame 1510. More specifically, in one example, the first screening core assembly 16010a may be grasped or otherwise attached to the first and second longitudinal members of the grid frame 1510. Additionally, the second screening unit 1610b may be gripped or otherwise attached to the second and third longitudinal members.

In some embodiments, each of the plurality of screen cartridge assemblies mounted or secured to the grid 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 implemented as a single injection molded piece integrally formed by injection molding of polyurethane, thermoset polymer, or other types of polymers. Example embodiments of injection molded articles and methods of forming injection molded articles are discussed in more detail in U.S. patent application No. 13/800,826, U.S. patent No. 9,409,209, U.S. patent No. 9,884,344, U.S. patent application No. 15/851,009, U.S. patent application No. 15/965,195, and cross-references contained therein, which are hereby incorporated by reference in their entirety. The housing and screen assemblies retained therein may have any shape and configuration suitable for mounting to a grid frame. In some embodiments, the housing and screen assemblies may be substantially rectangular. In other embodiments, the housing and screen assemblies may have a square shape, or may have an oval shape, or may have a triangular shape, etc.

As shown in FIG. 16B, the screening cartridge assembly 1610a includes a housing 1630a and a screen assembly with three screen units 1640 a. Note that the present disclosure is not limited to three screening units, and in some embodiments, may be implemented as fewer or additional screening units. For a defined size screening unit, a larger number of screening units results in a larger size housing 1630a and therefore a larger screening cartridge assembly. Larger screening cartridge assemblies can be used in grid frames with larger grid openings.

Housing 1630a includes a first opening configured to receive and/or fit the screen assembly within housing 1630 a. 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 grid frame 1510. The screening surface may be embodied as, or may comprise, for example, a substantially seamless and flat surface comprising a plurality of screening openings having, for example, a substantially uniform size and/or a substantially uniform shape. The plurality of screening openings may have a rectangular, square, circular, combinations thereof, and the like. In addition, as shown in FIG. 16C, housing 1630 also includes a ridge 1650a that extends from a first opening near a first edge of housing 1630a to an opposite second edge of housing 1630 a. The ridges 1650a and corresponding portions of the housing 1630a form respective notches that allow or otherwise facilitate mounting (e.g., clamping or clipping) of the housing 1630a to the grid frame 1510. The housing 1630a may be permanently mounted to the grid frame 1510 through the use of the ridges 1650a and various portions of the housing 1630a, or may be removably mounted to the grid frame 1510 such that the housing 1630a may be removed as needed for maintenance or repair.

Similarly, the screening cartridge assembly 1610b includes a housing 1630b and a screen assembly having three screen units 1640 b. As mentioned, the present disclosure is not limited to three screening units, and in some embodiments, may be implemented as fewer or additional screening units. Housing 1630b also includes a first opening configured to receive and/or fit the screen assembly within housing 1630 b. The housing 1630b also includes a second opening that allows the screening surface of the screen assembly to be exposed to the exterior of the grid frame 1510. The screening surface may be embodied as, or may comprise, for example, a substantially seamless and flat surface comprising a plurality of screening openings having, for example, substantially uniform sizes and/or substantially uniform shapes. In addition, as shown in FIG. 16C, housing 1630b further includes a ridge 1650b that extends from a first edge of housing 1630b proximate the first opening to an opposing second edge of housing 1630 b. The ridges 16650b and various portions of the housing 1630b can form corresponding notches that allow or otherwise facilitate mounting (e.g., clamping or clipping) of the housing 1630b to the grid frame 1510. With respect to the screen assemblies housed in housing 1630b, as further shown in fig. 16C and 17, which are housed in housing 1603b, each screen unit 1640b includes a frame unit having one or more screen elements secured to a surface of the frame unit, and the screen units 1640b may be mechanically bonded or otherwise secured together to form a screen assembly. To this end, each screening unit 1640, such as shown with reference to 1640b, may include one or more fasteners that may allow or otherwise facilitate securing a first one of the screening units (e.g., screening unit 1640a) to a second screening unit (e.g., l640 b). Regardless of the mechanism used to connect the screening unit 1640b, each screening element of the screening unit 1640 may form a screening surface that may be exposed to the slurry in the exterior of the grid frame 1510.

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

Similar to screening cartridge assemblies 1610a, 16010B, screening cartridge assembly 1610c also includes housing 1603c and a screening assembly having three screening units (not shown in fig. 16B). As mentioned, the present disclosure is not limited to three screening units, and in some embodiments, may be implemented as fewer or additional screening units. Housing 1630c also includes a first opening configured to receive and/or fit the screen assembly within housing 1630 c. The housing 1630c also includes a second opening that allows or otherwise facilitates exposure of the screening surface of the screen assembly to the exterior of the grid frame 1510. The screening surface may be embodied as, or may comprise, for example, a substantially seamless and flat surface comprising a plurality of screening openings having, for example, substantially uniform sizes and/or substantially uniform shapes. In addition, as shown in FIG. 16C, housing 1630C also includes a ridge 1650C that extends from a first opening near a first edge of housing 1630C to an opposite second edge of housing 1630C. The ridges 1650c and corresponding portions of the housing 1630c form respective notches that allow or otherwise facilitate mounting (e.g., clamping or clipping) of the housing 1630c to the grid frame 1510. Fig. 17 shows the mechanical coupling of

screen cartridge assemblies

1610a and 1610b to the transverse grid members of grid frame 1510. As described above, the ridges 1650a allow or otherwise facilitate mounting of the screening cartridge assembly 16010a to the grid frame 1510. Likewise, the ridges 1650b allow or otherwise facilitate mounting of the screening cartridge assembly 1610b to the grid frame 1510.

Screen cartridge assembly 1610a and screen cartridge assembly 1610b comprise respective screen assemblies. According to embodiments described herein, the screen assemblies housed in screen cartridge assembly 1610a include three screen units 1640 a. According to embodiments described herein, another screen assembly housed in screen cartridge assembly 1610b also includes three screen units. As mentioned, the present disclosure is not limited to screen assemblies having three screen units and, in some embodiments, may be implemented with fewer or additional screen units, as well as screen assemblies having different numbers of screen units.

In conjunction with the screen assemblies housed in housing 1630C, as further shown in fig. 16C, each of the screen units making up the screen assemblies includes a frame unit having screen elements secured to a surface of the frame unit. The screen units may be mechanically joined or otherwise secured together to form a screen assembly. To this end, in one embodiment, each of the screening units may include one or more fasteners that may allow or otherwise facilitate securing a first one of the screening units to a second one of the screening units. Regardless of the mechanism used to attach the screening units, the individual screening elements of the screening unit 1640 may form a screening surface that may be exposed to the exterior of the grid frame 1510.

It should be noted that although three screening cartridge assemblies are shown in fig. 16A-16C and 17, the entire or substantially the entire grid frame 1510 of the basket 1600 may be covered for operation in the separation process. As such, in an example embodiment, in an embodiment of the grid frame 1510, 264 screening cartridge assemblies may be installed into corresponding 264 square openings 1513.

Figure 18A illustrates a perspective view of an exemplary screening filter cartridge assembly 1800 in accordance with one or more embodiments of the present disclosure. The exemplary screen cartridge assembly 1800 includes a housing 1810 and screen assemblies with three screen units 1830. As mentioned, the present disclosure is not limited to three screening units, and in some embodiments, may be implemented as fewer or additional screening units. Housing 1810 has a generally arcuate shape and includes a first opening configured to receive and/or fit the screen assemblies within housing 1810. The housing also includes a first ridge 1820a and a second ridge 1820 b. Each of

ridges

1820a and 1820b extends from near a first top edge of shell 1810 to near an opposite second bottom edge of shell 1810. In use, the arcuate shape of the housing 1810 allows the distance between the outer impeller blades of the screening device and the screening cartridge assembly to be substantially uniform, thereby reducing clogging and extending the life of the screening elements.

Similar to other screen cartridge assemblies of the present disclosure, as shown in the top cross-sectional view 1850 of the screen cartridge assembly 1800 shown in fig. 18B, each screen unit 1830 may include two end frame units 1855 and a single middle frame unit 1857, each of the two end frame units 1855 and the single middle frame unit 1857 having screen elements 1860 attached to respective surfaces of the frame units.

The screening elements 1830 may be mechanically bonded or otherwise secured together to form a screen assembly. To this end, in one embodiment, each of the screening units 1830 may include one or more fasteners that may allow or otherwise facilitate securing a first one of the screening units 1830 to a second one of the screening units 1830. Regardless of the mechanism used to connect the screening units, the individual screening elements of the screening unit 1830 may form the screening surface of the screening cartridge assembly 1800. Housing 1810 also includes openings allowing at least a portion of the screening surface to be exposed as shown in side view 1890 of screening cartridge assembly 1800 in fig. 18B.

As shown at 1850 and 1870 in the cross-sectional view shown in fig. 18B, the housing 1810 may include an attachment frame portion 1852 and a retainer frame portion 1854. Also shown in the perspective view of the housing 1810 shown in fig. 19A are an attachment frame portion 1852 and a retainer frame portion 1854. The retainer frame portion 1854 may receive and/or retain screen assemblies formed by the screen units 1830. To that end, in some embodiments, retainer frame portion 1854 includes opening 1910 and an interior sidewall including sidewall 1920, sidewall 1930 and sidewall 1940. The other interior side walls are not visible in the perspective view of fig. 19A. For example, as shown in 1950 in the cross-sectional view of the housing 1810 shown in fig. 19B, a sidewall 1960 opposite the sidewall 1920 and a sidewall 1980 opposite the sidewall 1930 are also included in the inner sidewall of the holder frame portion 1854. The sidewall 1920 joining the

sidewalls

1930 and 1980 can define a first opening, and the opposing sidewall 1960 joining the

sidewalls

1930 and 1980 can define a second opening. The cross-sectional area of the second opening may be larger than the cross-sectional area of the first opening to mitigate undesirable reduction in screening area. The smaller cross-section may provide greater mechanical stability to screen assemblies disposed within housing 1810. The first and second openings may allow particulate matter to flow from the exterior to the interior of the screening cartridge assembly including housing 1810. Particulate matter may be screened or separated by such screen assemblies. In particular, particulate matter may be separated from slurry outside of a basket apparatus having a screening filter element assembly including screen assemblies, and may flow to an interior region of the basket apparatus as intended or required for screening applications (e.g., CIL processes, CIP processes, ore processing, water desalination, etc.).

As further shown in

cross-sectional views

1870 and 1970 in fig. 18B and 19B, retainer frame portion 1854 may include ridges 1872 near the opening configured to receive the screen assemblies and ridges 1874 near the bottom of housing 1810, respectively.

Additionally, with further reference to fig. 19A, the attachment frame portion 1852 includes an interior sidewall that includes the sidewall 1946 and the sidewall 1948, and other sidewalls opposite thereto, respectively. One of these opposing sidewalls may be collected in side view 1990 of fig. 19B. Specifically, sidewall 1992 is opposite sidewall 1946. The attachment frame portion 1852 also includes a ridge 1820a and a ridge 1820 b. In one embodiment, the

ridges

1820a, 1820b and the respective portions of the attachment frame portion 1852 form respective notches 1856. As mentioned, such notches may allow or otherwise facilitate mounting (e.g., clamping, grasping or otherwise engaging) of the screen cartridge assembly 1800 to a grid frame of the present disclosure, such as the grid frame 1510 disclosed hereinabove. By way of illustration, fig. 19C shows four housings 1810 mounted adjacent to one another on a grid frame 1510. Four screen assemblies may be inserted or otherwise assembled into the four housings 1810, respectively, to form four screen cartridges and assemble screen baskets for various separation processes, such as CIL processes, CIP processes, water filtration and desalination, and the like.

Figure 20A shows an example of screen assemblies 2000 in accordance with one or more embodiments of the present disclosure. The example screen assembly 2000 may be arranged or otherwise assembled within the housing 1810 or any other housing described herein to form a screening cartridge assembly according to the present disclosure. Consistent with other screen assemblies disclosed herein, screen assembly 2000 includes three frame units, which may include two end frame units 1855 and a single middle frame unit 1857, each of the end frame units 1855 and middle frame units 1857 including screen elements 1860 secured thereto. The present disclosure is not limited to three

frame units

1855, 1857 and/or a particular number of screen elements 1860 per

frame unit

1855, 1857. In some embodiments, two screen elements 1860 may be attached to each of the three

frame units

1855, 1857. In some embodiments, fewer or

additional frame units

1855, 1857 and/or screen elements 1860 may be implemented. Each (or in some embodiments, at least one) of the

frame units

1855, 1857 may be implemented as a single injection molded piece integrally formed by injection molding of a polymer.

Frame units

1855, 1857 may be mechanically joined or otherwise secured together to form screen assembly 2000. To this end, in one embodiment, each of

frame elements

1855, 1857 may include one or more fasteners that may allow or otherwise facilitate fastening a first one of

frame elements

1855, 1857 to a second one of

frame elements

1855, 1857. Regardless of the mechanism utilized or relied upon for joining the frame elements, the joined

frame elements

1855, 1857 form a first segmented edge member and an opposing second segmented edge member (not visible in fig. 20A). The joined

frame units

1855, 1857 also include first and second integral edge members (not visible in fig. 20A) corresponding to the edge members of the

outer frame units

1855, 1857, respectively.

The screen elements 1860 secured to each of the

frame units

1855, 1857 may form the screening surface of the screen assembly 2000 and the screen filter element assembly including the screen assembly 2000. As shown in

cross-sectional views

2050 and 2070 of screen assembly 2000 in fig. 20B, the screening surfaces may be substantially seamless. In some embodiments, as shown in side view 2090 of screen assembly 2000 in fig. 20, each (or in other embodiments, at least one) screen element 1860 of a screen assembly may include four adjacent sections with corresponding sets of screen openings. Such portions may be separated by support members (shown in phantom in plan view 2090). The present disclosure is not limited to screening elements having four portions and, in some embodiments, may be implemented with fewer or additional portions of the screening openings.

Fig. 21A illustrates a perspective view of a middle frame unit 1857, according to one or more embodiments of the present disclosure. The middle frame element 1857 is elongated and includes longitudinal side members 2138 that are opposite and substantially parallel to each other. The middle frame element 1857 also includes transverse side members 2136 that are opposite and substantially parallel to each other. Each of the lateral side members 2136 is substantially perpendicular to the longitudinal side members 2138. As mentioned, middle frame element 1857 may include a fastening mechanism that allows or otherwise facilitates mechanically joining or securing middle frame element 1857 and another frame element (end frame element 1855 or middle frame element 1857) together. Specifically, in some embodiments, fastening mechanisms can be assembled or otherwise formed on respective portions of the longitudinal side members 2138, while the lateral side members 2136 lack fastening mechanisms. Referring to fig. 21A, in at least one of such embodiments, the fastening mechanism may be embodied in the clip 2142 and the clip hole 2140 or may include the clip 2142 and the clip hole 2140. The middle frame unit 1857 and another frame unit (e.g., end frame unit 1855) that also has clips 2142 and clip apertures 2140 may be mechanically joined or otherwise secured together along their respective longitudinal side members 2138. To this end, in one embodiment, the clip 2142 of the middle frame unit 1857 may be passed into 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 members of the other frame unit. When the clips 2142 are pushed into the clip apertures 2140, the extension members of the clips 2142 may be forced together until the gripping portion of each extension member exceeds the longitudinal side members of the other frame unit, allowing the gripping portions to engage the interior of the longitudinal side members of the other frame unit. When the clip portions are engaged into the clip apertures 2140, the longitudinal side members of two separate frame units may be side-by-side and secured together (e.g., mechanically joined). The frame units may be separated by applying a force to the extension members of the clip, thereby moving the extension members toward each other to allow the clip portion to pass through the clip hole 2140. Although the fasteners described herein and shown in the drawings are clips and clip apertures, the present disclosure is not limited in this regard and alternative fasteners and clip and/or aperture alternatives may be used, including other mechanical devices, adhesives, and the like.

The middle frame unit 1857 also includes longitudinal support members 2146 and lateral support members 2148. Each longitudinal support member 2146 is substantially parallel to the longitudinal side members 2138 and substantially perpendicular to the lateral side members 2136. Each of the lateral support members 2148 is substantially parallel to the lateral side members 2136 and substantially perpendicular to the longitudinal support members 2146. The longitudinal support members 2146 and the lateral support members 2148 define a plurality of grid openings at least partially within the middle frame cell 1857. In addition, the longitudinal support members 2146 and the lateral support members 2148 may provide mechanical stability to the screen elements secured to the middle frame unit 1857.

The middle frame unit 1857 may also include second lateral support members 2145 that are substantially perpendicular to the longitudinal side members 2138. As shown in the side view 2170 in fig. 21A and 21B, the second lateral support members 2145 may be distributed over the grid openings in the middle frame unit 1857. The second lateral support members 2145 may provide further mechanical stability to the screen elements secured to the middle frame unit 1857.

To allow or otherwise facilitate the fixing of one or more screening elements to the middle frame unit 1857, attachment members 2144 and several adhesive arrangements are provided in the middle frame unit 1857. As shown in side view 2190 of the middle frame element 1857 shown in fig. 21B, the first adhesive arrangement includes a plurality of fused strips 2172 assembled (e.g., formed) on the surfaces of the longitudinal side members 2138. As shown in the top view 2150 of the middle frame unit 1857 in fig. 21B, the second adhesive arrangement includes a plurality of weld bars 2152 assembled (e.g., formed) on the surfaces of the lateral side members 2136 and the lateral support members 2148. As shown in the side view 2170 of the middle frame element 1857 in fig. 21B, the third adhesive arrangement includes a plurality of frit strips 2176. In some embodiments, the height of the welding strip 2176 may be less than the height of the welding strip 2172, and also less than the height of the welding strip 2152.

In some embodiments, the attachment members 2144 may allow or otherwise facilitate alignment of the screen elements for laser welding to the middle frame unit 1857 or another type of frame unit disclosed herein. The attachment members 2144 and/or various welding strips may melt during laser welding.

The end frame elements 1855 may have a similar structure to the middle frame element 1857. The fastening mechanism in the end frame unit 1855 may be included in a single longitudinal side member of the frame unit 1855.

In some embodiments, the screen elements may be implemented in screen elements 1860 as shown in fig. 22A or may be included in screen elements 1860 as shown in fig. 22A. The screen element 1860 includes a first side portion 2220 and a second side portion 2222 that form a seamless periphery. 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 second side portion 2222 is substantially perpendicular to the first side portion 2220. Each of the side portions 2220 is configured to rest on and be secured to lateral side members (e.g., members 2136) of frame cells 1855, 1857 (e.g., middle frame cell 1857) according to embodiments of the present disclosure. As such, each of the side portions 2220 may include a cavity configured to receive or otherwise engage a welding strip on a surface of the lateral side member.

The screen element 1860 also includes several support members. More specifically, screen element 1860 includes

support members

2230 and 2238. Support member 2230 is substantially collinear with and substantially perpendicular to support member 2238. Support members 2238 are also substantially collinear. The screening element 1860 also includes support members 2240 that extend from a first one of the side portions 2222 to a second one of the second side portions 2222. Each of the

support members

2230, 2238 and 2240 is configured to rest or be secured on a respective support member of a frame unit 1855, 1857 (e.g., middle frame unit 1857). Thus, each of the

support members

2230, 2238 and 2240 includes a cavity configured to receive or otherwise engage the welded strip on the respective surface of the support member of the frame unit.

The screen element 1860 also includes attachment apertures 2224. One of the attachment holes 2224 is located substantially in the centre of the screen element 1860. Other attachment apertures 2224 are located at each corner of the seamless periphery of the screen element 1860. Regardless of the location in the screening element 1860, each of the attachment apertures 2224 (or, in some embodiments, at least one) is configured to allow or otherwise facilitate the ability of an elongated attachment member 2144 (see, e.g., fig. 21A) to pass through the attachment aperture 2224. In one or more such embodiments, the attachment holes 2224 may comprise tapered holes that may be filled when a portion of the elongated attachment members 2144 melt over the screening surface of the screen element 1860, thereby securing the screen element 1860 to the intermediate frame unit 1857 or another type of frame unit disclosed herein. In other embodiments, the attachment holes 2224 may be configured without tapered holes, allowing beads to form on the screening surface 2013 of the screening element 1860 when a portion of the elongated attachment members 2144 melt over such screening surface, securing the screening element 1860 to the intermediate frame unit 1857 or another type of frame unit disclosed herein. The screen element 1860 may cover half of the middle frame unit 1857 (or another type of frame unit disclosed herein), and each of the four sections included in the screen element 1860 may cover four grille openings of the middle frame unit 1857, respectively.

Screening surface 2213 has a plurality of screening openings. Each of the plurality of screening openings (or, in some embodiments, at least some) may be elongated and may have a defined length L and a defined width W (e.g., see fig. 22C and related description below) with screening applications (e.g., CIL processes, CIP processes, ore processing, water desalination, etc.) based on the use of the screening elements 1860 therein.

Referring to fig. 22A and 22B (showing top and

side views

2250, 2270, and 2290 of the screen element 1860), multiple openings may be arranged in segments, with the screen openings in each segment arranged in a grid. Each section is at least partially defined by

support members

2230, 2238 and 2240 of the screen element 1860. In one embodiment, the screen openings adjacent to the periphery of screen element 1860 may be defined by longitudinal ribs parallel to the first side of screen element 1860, transverse ribs perpendicular to the longitudinal ribs, and edge segments of the side of screen element 1860. In addition, the screening openings in the interior of the cross-section may be defined by longitudinal ribs and transverse ribs. The longitudinal ribs define a major side of the elongated slot and the transverse ribs define a minor side of the elongated slot.

Figure 22C is an enlarged top view of a portion of a screening element according to an example embodiment of the present disclosure. Fig. 22C illustrates features common to various screens of the present disclosure, such as screen 1860 shown in fig. 22A and 22B. Referring to fig. 22C, the screening element includes surface elements 84 that extend parallel to screening element ends 2220 and form screening openings 86. The thickness T of the surface elements 84 may vary depending on the screening application and the configuration of the screening openings 86. In this example, the screening openings 86 are elongated slots having a length L and a width W, which may vary for a selected configuration. The thickness T of the surface element 84 may be about 43 μm to about 1000 μm (i.e., 0.0017 inches to 0.0394 inches), depending on the desired open screening area and the width W of the screening openings 86.

In some embodiments, the plurality of screening openings may have a substantially uniform length L, the length L being in a range of approximately 300 μm to 4000 μm (i.e., 0.0118 inches to 0.1575 inches) in size. Additionally, the plurality of screening openings may have a substantially uniform width W in a range of about 35 μm to about 4000 μm (i.e., 0.0014 inches to 0.1575 inches). By way of illustration, in some embodiments, the width W may be approximately equal in size to 43 μm (i.e., 0.0017 inches), 74 μm (i.e., 0.0029 inches), 90 μm (i.e., 0.0035 inches), 104 μm (i.e., 0.0041 inches), 125 μm (i.e., 0.0049 inches), 150 μm (i.e., 0.0059 inches), 180 μm (i.e., 0.0071 inches), 500 μm (i.e., 0.0197 inches), 700 μm (i.e., 0.0276 inches), or 1000 μm (i.e., 0.0394 inches 1 mm). In one exemplary embodiment, the plurality of screening openings may have a substantially uniform length L, which is about 500 μm (i.e., 0.0197 inches) in length.

Table 1 (below) illustrates several exemplary configurations of surface elements 84 and screening openings 86.

TABLE 1

Table 2 (below) illustrates further exemplary configurations of the cover elements 84 and screening openings 86. In the depicted example, the surface element 84 has a fixed thickness T of 0.014 inches. The screening opening 86 has a fixed length L of 0.076 inches and a variable width W. It is contemplated that for a fixed number of screening openings 86, the percentage open area decreases with the width W of each screening opening 86. In this example, the percentage open area varies from 6.2% for a minimum open area of 0.0017 inches for a minimum width W to 23.3% for a maximum open area of 0.0071 inches for a maximum width W.

TABLE 2

Number of meshes	W (inch)	T (inch)	L (inch)	% area of opening
					80	0.0071	0.014	0.076	23.3
100	0.0059	0.014	0.076	20.3
					120	0.0049	0.014	0.076	17.6
140	0.0041	0.014	0.076	13.4
					170	0.0035	0.014	0.076	12.2
200	0.0029	0.014	0.076	10.3
					230	0.0025	0.014	0.076	9.1
270	0.0021	0.014	0.076	7.9
					325	0.0017	0.014	0.076	6.2

Table 3 (below) shows further exemplary configurations of surface elements 84 and screening openings 86. Table 3 illustrates the effect of reducing the length L of the screening openings 86 and reducing the width T of the surface elements 84 so that the screening element 1860 may include more screening elements. In this example, the surface element 84 has a fixed thickness T of 0.007 inches. The screening opening 86 has a fixed length L of 0.046 inches and a variable width W. The resulting percentage open area varied from a minimum open area of 10.1% for a minimum width W of 0.0017 inches to a maximum open area of 27.3% for a maximum width W of 0.0071 inches. Thus, by comparing the results of tables 3 and 2, it can be seen that by reducing T from 0.014 inches to 0.007 inches, and by reducing L from 0.076 inches to 0.046 inches, the maximum open area percentage increased from 23.3% to 27.3%. As discussed above, the maximum percentage of open area is increased because more screen openings may be included in the screen element 1860 as the size of the screen openings 86 and surface features decrease.

TABLE 3

Table 4 (below) illustrates a further exemplary configuration of surface elements 84 and screening openings 86. Table 4 shows that this trend may continue. In this example, the surface element 84 has a fixed thickness T of 0.005 inches. The screening opening 86 has a fixed length L of 0.032 inches and a variable width W. The resulting percentage open area varied from a minimum open area of 12.1% for a minimum width W of 0.0017 inches to a maximum open area of 31.4% for a maximum width W of 0.0071 inches. Thus, by comparing the results of tables 3 and 4, it can be seen that by reducing T from 0.007 inches to 0.005 inches, and L from 0.046 inches to 0.032 inches, the maximum open area percentage increased from 27.3% to 31.4%.

TABLE 4

Number of meshes	W (inch)	T (inch)	L (inch)	% area of opening
					80	0.0071	0.005	0.032	31.4
100	0.0059	0.005	0.032	29.3
					120	0.0049	0.005	0.032	27.0
140	0.0041	0.005	0.032	24.1
					170	0.0035	0.005	0.032	22.0
200	0.0029	0.005	0.032	19.7
					230	0.0025	0.005	0.032	16.4
270	0.0021	0.005	0.032	14.7
					325	0.0017	0.005	0.032	12.1

As shown in fig. 23A and 23B, some embodiments may include a fastening mechanism in the frame unit (middle frame unit 2357 or end frame unit 2355) that may allow or otherwise facilitate assembly of screen assembly 2300 with a certain curvature. In one of such embodiments, the fastening mechanism may include clips and clip apertures such that assembled screen assembly 2300 is curved, rather than substantially planar, as shown in

side views

2350, 2570, and 2390 of curved screen assembly 2300 shown in fig. 23B.

Fig. 24 and 25 show an alternative embodiment of a screening core assembly 2400 for a screen basket of the present disclosure. The filter cartridge assembly 2400 includes a removable housing having a top housing portion 2410 and a separate bottom housing portion 2411. Top and

bottom housing portions

2410 and 2411 each include an attachment mechanism 2440, which attachment mechanism 2440 is removably engageable with apertures 2445 provided on top and

bottom housing portions

2410 and 2411. In use, screen assemblies with screen units 2430 may be fitted into top housing portion 2410 or bottom housing portion 2411, and then the opposite housing portion may be fitted around the screen assemblies through screen units 2430. Attachment mechanism 2440 engages apertures 2445 to securely fix screen assemblies with screen units 2430 within the housing.

The removable housing having a top housing portion 2410 and a bottom housing portion 2411 includes substantially the same features as housing 1810 discussed herein, including an attachment frame portion, a retainer frame portion, and a ridge. As shown in the perspective view of the bottom housing portion 2411 shown in fig. 25, the attachment frame portion 2452 includes interior sidewalls and

attachment ridges

2420a and 2420b that allow or otherwise facilitate mounting (e.g., clamping, grasping or otherwise engaging) the screening cartridge assembly 2410 to a grid frame of the present disclosure, such as the grid frame 1510. The retainer frame section 2454 may receive and/or retain screen assemblies formed from screening units in a substantially similar manner as the retainer frame section 1854 of the housing 1800 discussed in more detail herein.

Top housing portion 2410 and bottom housing portion 2411 may each be formed from a single injection molded piece that is integrally formed by injection molding of polyurethane, thermoset polymer, or other types of polymers. For a single housing (e.g., housing 1810), top housing portion 2410 and bottom housing portion 2411 may be more easily formed by an injection molding process due to the relative simplicity of the separate top housing portion 2410 and bottom housing portion 2411. Exemplary embodiments of injection molding processes are discussed in greater detail in U.S. patent application No. 13/800,826, U.S. patent No. 9,409,209, U.S. patent No. 9,884,344, U.S. patent application No. 15/851,009, U.S. patent application No. 15/965,195, and the cross-referenced disclosures included therein, which are incorporated herein by reference in their entirety.

While embodiments of the present disclosure have been described with reference to various implementations 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. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments.

Claims

1. A screen basket apparatus comprising:

a grid frame having a plurality of openings arranged in a grid, wherein the grid frame has a first end and an opposing second end, the grid frame including a plurality of cross members and a plurality of longitudinal members defining the plurality of openings; and

a plurality of screen cartridge assemblies secured to the grid frame to cover respective openings, wherein a first screen cartridge assembly of the plurality of screen cartridge assemblies includes a first housing and a first screen assembly fitted into the first housing, wherein a second screen cartridge assembly of the plurality of screen cartridge assemblies includes a second housing and a second screen assembly fitted into the second housing;

wherein each of the first screen assembly and the second screen assembly includes a screen element having a plurality of screen openings,

wherein the first screening filter element assembly is secured to a first cross member and a second cross member of the plurality of cross members; and

wherein the second screening filter element assembly is fixed to a second cross member and a third cross member of the plurality of cross members.

2. The screen basket apparatus of claim 1, wherein the screening openings are at least one of rectangular, square, circular, or a combination thereof.

3. The screen basket apparatus of claim 1, wherein the screening openings have a length L in a range of about 300 μ ι η to about 4000 μ ι η in size and a width W in a range of about 35 μ ι η to about 4000 μ ι η in size.

4. The screen basket apparatus of claim 1, wherein the first housing comprises a single injection molded piece integrally formed by one of injection molding of polyurethane or thermoset polymer.

5. The basket apparatus of claim 3, wherein the first screen assembly comprises:

a plurality of mechanically interlocked frame units, wherein each of the plurality of frame units comprises structural members forming a grid opening; and

a plurality of screen elements, wherein groups of the plurality of screen elements are secured to the plurality of frame units, respectively.

6. The screen basket apparatus of claim 5 wherein a frame unit of the plurality of frame units is elongated and comprises:

a first longitudinal side member and a second longitudinal side member opposite and substantially parallel to the first longitudinal side member; and

a first lateral side member and a second lateral side member opposite and substantially parallel to the first longitudinal side member; wherein the first lateral side member is perpendicular to each of the first and second longitudinal side members; and wherein the second lateral side member is substantially perpendicular to each of the first and second longitudinal side members.

7. The screen basket apparatus of claim 5, wherein the screen elements of the plurality of screen elements comprise a single injection molded piece integrally formed by injection molding of a thermoplastic material.

8. A screen basket apparatus as recited in claim 7, wherein the screening element includes a substantially planar screening surface having a plurality of screening openings that are elongated slots.

9. The screen basket apparatus of claim 7, wherein the screening element includes surface elements having a thickness T, the thickness T having a magnitude in a range of approximately 43 μm to approximately 100 μm.

10. The screen basket apparatus of claim 9, wherein the width W is substantially uniform and is about 43, 74, 90, 125, 150, 180, 500, or 700 μ ι η in size.

11. The screen basket apparatus of claim 9, wherein:

the length L of the screening opening is approximately 0.1295 inches;

the width W of the screening opening is about 0.0182 inches; and is

The surface element has a thickness T of about 0.0283 inches.

12. The screen basket apparatus of claim 9, wherein:

the length L of the screening opening is approximately 0.1295 inches;

the width W of the screening opening is about 0.0214 inches; and is

The surface element has a thickness T of about 0.0252 inches.

13. The screen basket apparatus of claim 9, wherein:

the length L of the screening opening is approximately 0.1295 inches;

the width W of the screening opening is about 0.0262 inches; and is

The surface element has a thickness T of about 0.0341 inches.

14. A screening cartridge assembly comprising:

a housing comprising a retainer frame portion and an attachment frame portion seamlessly integrated into a single unit; and

a screen assembly configured to fit within the housing;

wherein the retainer frame portion is configured to receive the screen assemblies;

wherein the attachment frame portion comprises a first elongate ridge extending along an edge of the attachment frame portion and a second elongate ridge extending along an opposite edge of the attachment frame portion; and is

Wherein the attachment frame portion is configured to attach to a frame of a screening device;

wherein the screen assembly includes a screen element having a plurality of openings with a length L in the range of about 300 μm to about 4000 μm and a width W in the range of about 35 μm to about 4000 μm.

15. The screening filter assembly of claim 14, wherein said screen assembly includes:

a plurality of mechanically interlocked frame units, wherein each of the plurality of frame units comprises a structural member forming a grid opening; and

16. A screen element comprising:

a screening opening having a substantially uniform width W and a substantially uniform length L, wherein the width W of the screening opening is approximately: 35 μm W4000 μm and the length L of the sieving opening is approximately: l is more than or equal to 300 mu m and less than or equal to 4000 mu m; and

surface elements separating the screening openings, the surface elements having a thickness T of approximately 70 μm T400 μm;

wherein the screen element has an open screening area that is about 5% to about 35% of the total area of the screening surface.

17. The screening element of claim 16, wherein said screening openings are elongated slots.

18. The screen element of claim 16, wherein the screen openings are rectangular, square, circular, or a combination thereof.

19. The screen element of claim 16, wherein:

the length L of the screening opening is approximately 0.1295 inches;

the width W of the screening opening is about 0.0182 inches; and is

The surface element has a thickness T of about 0.0283 inches;

20. the screen element of claim 16, wherein:

the length L of the screening opening is approximately 0.1295 inches;

the width W of the screening opening is about 0.0214 inches; and is

The surface element has a thickness T of about 0.0252 inches.

21. The screen element of claim 16, wherein:

the length L of the screening opening is about 0.1295 inches;

the width W of the screening opening is about 0.0262 inches; and is

The surface element has a thickness T of about 0.0341 inches.

22. The screen assembly according to claim 16, wherein:

the surface element has a thickness T of about 356 μm;

the length L of the screening opening is about 1.9 mm; and is

When the width W of the sieving openings varies in the range of about 45 to 180 μm, the opening sieving area varies between about 6 to 24%.

23. The screen assembly according to claim 16, wherein:

the thickness T of the surface element is approximately 178 μm;

the length L of the screening opening is about 1.2 mm; and is

When the width W of the sieving openings varies in the range of about 45 to 180 μm, the opening sieving area varies between about 10 to 28%.

24. The screen assembly according to claim 16, wherein:

the thickness T of the surface element is about 127 μm;

the length L of the screening opening is about 0.8 mm; and is

The open screening area varies between about 12% and 32% when the width of the screening openings varies from about 45 μm to 180 μm.

25. The screen assembly according to claim 16, wherein:

the surface element thickness T is about 76 μm;

the length L of the screening opening is about 0.7 mm; and

the open screening area varies between about 13% and 33% when the width of the screening openings varies in the range of about 45 μm to 180 μm.