CN113165020B

CN113165020B - Method and apparatus for sieving

Info

Publication number: CN113165020B
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: 2023-10-20
Anticipated expiration: 2039-10-04
Also published as: TWD203476S; CL2018003507S1; CO2021005759A2; AU2019355180B2; ZA202102970B; AU2019355180A1; JP7432587B2; WO2020072932A3; PE20211622A1; DOP2021000057A; BR102018075348B1; CL2021000834A1; WO2020072932A2; MX2021003922A; CN113165020A; EA202190971A1; KR20190003090U; JP2022504064A; BR102018075348A2; FI12523U1

Abstract

Methods and apparatus for screening are provided. Embodiments include a screen basket (1) apparatus for screening material, the screen basket apparatus including a grid frame (1510) having a plurality of openings arranged in a grid pattern and a plurality of screen 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 a screen assembly (2000) mounted in the housing (1630) and securable 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 generally continuous screening surface across the exterior of the grid frame (1510), which reduces clogging and wear resistance.

Description

Method and apparatus for sieving

Cross Reference to Related Applications

The present application claims priority from U.S. patent application Ser. No. 16/151,909, which is a continuation-in-part application of U.S. patent application Ser. No. 16/001,755, filed on 6 th month 6 of 2018, U.S. patent application Ser. No. 16/001,755 claims the benefit of U.S. patent application Ser. No. 62/515,964, filed on 6 th month 6 of 2017, and U.S. patent application Ser. No. 62/615,302, filed on 9 1 month 1 of 2018, the contents of which are incorporated herein by reference, and claims priority.

Drawings

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

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

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

Fig. 3 illustrates a top 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 (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, according to an exemplary embodiment of the present disclosure.

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

Fig. 7 is a partial top view illustrating attachment of screening members 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 partial enlarged 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 cross-sectional view of fig. 9.

Fig. 10 illustrates an enlarged partial cross-sectional view taken substantially along line 10-10 of fig. 9, showing a modified shape cross-sectional configuration of a first member having a 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 reinforcing member, according to an example embodiment of the present disclosure.

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

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

Fig. 14 illustrates a side cross-sectional view of the use of a screen basket in an embodiment of a screen separator device according to an exemplary embodiment of the present disclosure.

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

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

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

Fig. 16C shows a partial perspective view of the interior of the screen basket of fig. 16A featuring a plurality of screen cartridge assemblies according to an example embodiment of the present disclosure.

Fig. 17 illustrates a partial cross-sectional view of an exemplary screen cartridge assembly mounted on a grid frame in accordance with an exemplary embodiment of the present disclosure.

Fig. 18A shows a perspective view of an exemplary screen cartridge assembly according to an example embodiment of the present disclosure.

Fig. 18B shows a cross-sectional view and a side view of the exemplary screen cartridge assembly of fig. 18A. Example dimensions are shown in inches in the figures. The present disclosure is not limited to this size and other sizes are contemplated.

Fig. 19A shows a perspective view of a housing of an exemplary screen cartridge assembly according to an exemplary embodiment of the present disclosure.

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

Fig. 19C illustrates an example of multiple shells secured to a grid frame of a basket in accordance with an exemplary embodiment of the present disclosure.

Fig. 20A shows an example screen assembly element according to an example embodiment of the present disclosure.

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

Fig. 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 unit of fig. 20A.

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

Figure 22B shows top and side views of the example screen element of figure 22A.

Fig. 22C is an enlarged top view of a portion of a screen element according to an example embodiment of the present disclosure.

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

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

Fig. 24 illustrates an example of a cartridge screen element according to an example embodiment of the present disclosure.

Fig. 25 shows an example of a bottom housing portion of the cartridge screen element of fig. 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 metals from metal-bearing ores. Embodiments of the present disclosure may be used with Carbon In Pulp (CIP), leached Carbon (CIL) systems, and leached Resin (RIL) systems. For example, CIL and CIP systems are two countercurrent 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 slurry stream flows continuously from the first tank to the last tank in the series. At the same time, carbon is pumped counter-currently from the last tank in the series to the first tank. The CIP and CIP processes differ in the extent of gold leaching prior to carbon adsorption. For example, in CIL operation, carbon is added to the leaching tank and leaching reactions and adsorption occur simultaneously. In contrast, in CIP processes, a large portion of leachable gold is leached prior to the first adsorption stage.

A description of a general process for recovering gold from gold-bearing ores using a combination of cyanidation and adsorption treatments can be found in us patent 4,188,208. Although embodiments of the present disclosure are generally discussed with reference to gold or carbon, embodiments of the present disclosure are equally applicable to processes for recovering silver, iron, nickel and other metals from suitable ores. Recovery of any metal from mined ore is within the scope of the present disclosure.

A description of existing metal screen baskets and methods of their use in the CIP process described above can be found in U.S. patent No. 5,238,117. The method described in U.S. patent 5,238,117 is commonly referred to in the art as the "NKM" vertical sweep interstage screening process, and the screen basket used therein is commonly referred to in the art as the 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 walls. Wedge wire screens are used to filter material from a metal-rich slurry. The screen basket is attached to the NKM screen apparatus and the lower portion of the NKM screen apparatus (including the attached NKM screen basket) is submerged in a tank containing carbon in slurry (CIP) material. Impellers on NKM screening devices pass the slurry in the tank through wedge wire screens and into the interior of the NKM screens. However, the open screening area of wedge wire screens is very small, resulting in inefficient screening. Low open screening areas can also lead to clogging. The plugging in turn forces the increased slurry to 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 screening, 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 material 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 side walls extend around and are supported by the side wall support portions. The polyurethane screen side wall includes a polyurethane screen of high open area. In certain embodiments, the polyurethane screen side walls substantially enclose the side wall support portion between the closed bottom and the open top, thereby providing a maximum screening area. The polyurethane screen sidewall may be fixed to the outer circumference 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 one another to provide a substantially continuous screening area through the screen sidewall. In one example, the plurality of individual polyurethane screen members may include eight individual polyurethane screen members. In such an embodiment, the eight individual polyurethane screen members may be arranged such that four of the screen members are on the lower half of the support frame and four of the screen members are on the upper half of the support frame.

In some embodiments, the substantially closed bottom may be provided with a central aperture allowing receiving a drive shaft of the NKM device.

In certain embodiments, the high open area polyurethane screening element 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 openings; a set of second substantially parallel flexible members defining second opposite sides of the screening openings, 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; a substantially parallel side edge portion on opposite sides of the body, a third member extending between the side edge portions; first and second substantially parallel ends at opposite ends of the body, a fourth member extending between the first and second ends, whereby the ends are substantially perpendicular to the edge portion. The screen openings in the flexible molded polyurethane body of the polyurethane screen 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 reinforcing member integrally molded in at least one of the first member and the third member and in at least one of the second member and the fourth member. In some embodiments, the reinforcement member integrally formed in the first member may have a substantially uniform thickness ranging in size from about 0.006 inches to about 0.015 inches. The reinforcement member integrally molded with the second member may have a substantially uniform thickness ranging in size from about 0.015 inch to about 0.040 inch. The stiffening member may be embodied as a rod, for example, which may be integrally molded with the member. The reinforcing member may also be implemented as, for example, an aramid fiber that is at least one of a twisted and woven multi-strand fiber having a linear density of about 55 denier (denier) to about 2840 denier.

The side edge portions of the polyurethane screen member may be configured for attaching the screen member 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 arranged substantially perpendicularly with respect 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 of the plurality of openings (or, in some embodiments, at least some) 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. The second subset of the plurality of openings may be defined by longitudinal members and transverse segments of the first annular portion of the grid frame, and similarly the third subset of the plurality of openings may be defined by longitudinal members and transverse 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 installation of the basket into a screen separator (e.g., an interstage device that is vertically swept by NKMs).

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

In some embodiments, each of a plurality of screen cartridge assemblies mounted or secured to a 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 greater detail in U.S. patent application Ser. No. 13/800,826, U.S. patent application Ser. No. 9,409,209, U.S. patent application Ser. No. 9,884,344, U.S. patent application Ser. No. 15/851,009, U.S. patent application Ser. No. 15/965,195, and cross references contained therein, the entirety of which is incorporated herein by reference.

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 assemblies within the housing and a second opening that allows the screening surfaces of the screen assemblies to be exposed to the exterior of the grid frame. The housing further 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) of the housing to the grid frame.

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

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

A screening cartridge according to the present disclosure may be of any suitable shape for attachment to a grid frame of a basket. For example, but not limited to, the screening cartridges may be square, rectangular, or oval or any other shape. Although example embodiments may provide a screening cartridge that substantially matches the shape of the grid openings of the grid frame (i.e., a square screen cylinder on a grid frame having square grid openings), different shapes of screening cartridges may be secured to different shapes of grid openings. Similarly, the grid frame of the basket 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 metals and therefore have a longer life than wedge wire frames in CIL processes. The screen elements discussed herein also allow for the formation of significantly smaller screen openings compared to conventional wedge wire frames, which in turn increases screening efficiency. The use of the screening elements described herein provides a significantly larger screening area and significantly reduced blindness compared to conventional wedge wire screen baskets. In use, the screen elements and screen cartridges described herein also allow for a substantially uniform distance between the outer pusher vanes of the screen apparatus and the screen cartridge assembly, 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 thereto 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 a vertical support portion 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 of 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 main support members 531 spaced apart along the periphery of the frame 510, and a plurality of auxiliary support members 542 spaced apart between the main support members 531. The primary support member 531 and the secondary support member 542 together connect the upper end 51 and the lower end 515 of the frame 510 in a spaced apart arrangement. The horizontal support member 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 a spaced relationship across the rim 510.

As shown in fig. 3, each vertical support member 531 may include an inner post portion 532. The inner post portion 532 may in turn include a hole 534 therethrough. The horizontal support members 550 pass through the apertures 534, thereby securing the 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 openings to allow for receiving and processing 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 basket 1 during processing. The substantially closed bottom 516 may be provided with a central aperture 517 for operational arrangement with the shaft of the processing apparatus, 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 a frame 510, forming a screen basket 1 having an open top, a substantially solid or closed bottom 516, and polyurethane screen side walls 601.

Because of potential dimensional constraints during the molding process 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, polyurethane screen 600 may have a plurality of separate screening elements 10. Each screening element 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 for forming a polyurethane screen sidewall 601 of a screen basket 1. Fig. 4 to 5 show the outer side and the inner side, respectively, of an embodiment of a screening element 10. While figure 6 shows a side view of an embodiment of a screening element 10. The screening element 10 may comprise polyurethane screens described in more detail in the following patents and patent publications, which are assigned to the same assignee as the present disclosure and are incorporated herein by reference: 8,584,866, 9,010,539, 9,375,756, 9,403,192, 2015/0197827A1 and 2016/0303611A 1.

Referring to fig. 4-7, embodiments of the present disclosure may provide a screening member 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 screen members 10 to each other and for securing the screen members 10 to the basket 510, as shown in fig. 7. Each side edge portion 14, 16 may comprise 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 portion 29 may include a formed 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, etc. 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 further 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 portions 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. Fig. 4 depicts the outer surface 22 of the body 12 when the screening element 10 is secured to the rim 510, for example, as shown in fig. 1. Fig. 5 depicts the interior surface 24 of the body 12 when the screening element is secured to a rim 510 such as that shown in fig. 1. The body 12 includes a first member 101 and a second member 102 that form the screen openings 26, as shown in detail in fig. 8 and 8A. In some embodiments, the first member 101 and the second member 102 may be configured to include a stiffening member 50, discussed in more detail below. As shown in the side view of fig. 6, the screen element 10 may also include 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 vertical ribs 28.

The body 12 may further include a third member 203 and a fourth member 204. The third member 203 and the fourth member 204, and if present the vertical ribs 28, may also include a stiffening member 50, which will be discussed in more detail below. However, in certain embodiments of the present disclosure, the third member 203, the fourth member 204, and the vertical rib 28 may not include the reinforcing member 50. The third and fourth members 203, 204 are generally configured to provide support to the screening openings 26 formed by the first and second members 101, 102.

Fig. 8 shows a part of an embodiment of a screening element 10, fig. 8A depicts an enlarged view 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 openings 26. The third member 203 and the fourth member 204 may form a second integrally molded grid structure 200, and the fifth member 305 and the sixth member 306 may correspondingly form a third integrally molded grid structure 300.

The reinforcing members 50 may be incorporated into the desired components of the screen element 10. The reinforcing 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 reinforcing member 50 may be integrated with a suitable member (e.g., by integral molding). The reinforcing member 50 may be made of plastic, metal, polymer, or any other suitable material having the requisite structural characteristics. For example, the reinforcing members 50 may be implemented as rods integrally molded with the screening member. The reinforcing member 50 may also be implemented as an aramid fiber that is at least one of twisted and braided strands such that the fiber serves as a core to absorb polyurethane molded therearound, thereby providing a strong bond thereto. The linear density of the twisted or braided multi-ply fibers may be from about 55 denier to about 2840 denier, and may preferably be about 1500 denier. When aramid fibers are used in embodiments of the present disclosure, they may be under the trademark A group of aramid fibers available from dupont. The reinforcing member 50 may also be at least one of the commercially available aramid fibers under the trade names Teijin company TWARON, SULFRON, TEUINCONEX and TECHNORA. The flexibility of the aramid fibers provides a flexible stiffening system for the molded polyurethane that is capable of recovering its original molded shape after necessary bending and flexing during handling and installation. In some embodiments, the reinforcing member 50 may be tensioned prior to molding polyurethane around it.

Referring again to the example 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 a support grid within the members. Due to the nature of the reinforcing 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 opening 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 that is substantially parallel to each other and substantially perpendicular to the first members 101. In some 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 screen openings 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 reinforcing 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 screening element 10, the body 12 has a first element 101 and a second element 102, and the bi-directional reinforcing element 50 is integrally formed with the first element 101 and the second element 102. The thickness of the reinforcement 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 integrally formed with the second member 102 (not shown) is in the range of about 0.015 inch to about 0.040 inch. Such a configuration may be beneficial for screening applications requiring a larger screening opening.

Embodiments of the present disclosure may incorporate the reinforcing member 50 in any one 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 detail in fig. 8 and 8A, the sizing openings 26 may be elongated with a length dimension along their sides and ends that is greater than the width dimension. The width of the screening openings 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 sizing openings 26 may be about 0.44mm to about 60mm, which is the dimension between the inner surfaces of adjacent second members 102. The screening openings 26 may additionally have various different shapes. For example, the sizing 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 to be understood that all dimensions set forth herein are exemplary only and not limiting.

Referring briefly to fig. 10 and 11, the screen openings 26 may taper downwardly between the outer surface 22 and the inner surface 24 with the first member 101 being substantially inverted trapezoidal in shape. This generally trapezoidal shape of the first member 101 prevents clogging in the screen element 10 and the entire polyurethane screen 600. The first member 101 may include the reinforcing member 50 integrally molded with the first member 101 as shown in fig. 10, or may not include the 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 member 203 and the fourth member 204 may provide additional structural support for the first member 101 and the second member 102. As shown in the exemplary embodiment of fig. 8 and 8A, the third member 203 may extend laterally between the side edge portions 14, 16 in a substantially parallel manner to one another, and may have a plurality of first members 101 therebetween. The fourth member 204 may extend laterally between the lower edge portion 18 and the upper edge portion 20 in a substantially parallel manner to one another 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 stiffening member 50 while maintaining the necessary structural support to 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 the third member 203 and the fourth member 204, and the additional support of the reinforcing members 50 integrated therein, if included, greatly reduces the thickness of the support members 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. 4-6, a series of nine ribs 28 may be provided. The rib 28 may have a thickness greater than the thickness of the third member 203 and the fourth member 204 and may have a portion that extends 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 walls 601. The greater thickness and positioning of the ribs 28 provides additional structural support for the first member 10 and the second member 102.

The ribs 28 may extend transversely between the lower edge portion 18 and the upper edge portion 20 in a substantially parallel manner to one another 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 one another, and may have a plurality of third members 203 therebetween. The ribs 28 may have reinforcing members 50 integrally molded therein. Ribs 28 may provide additional support for screening openings 26 and may be configured to have a minimum thickness by including reinforcing members 50 while providing the necessary structural support to retain screening openings 26 during vibratory screening applications. Like the third member 203 and the fourth member 204, the support system provided with the ribs 28 greatly reduces the thickness of the support members and provides increased open screening area and overall screening efficiency.

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

Each screening element 10 capable of incorporating such reinforcing members 50 may comprise zero, one or more reinforcing members 50 and the reinforcing members 50 used therein may be of different sizes and materials. The reinforcing members 50 may be located in the lower half of the members so as not to be exposed relatively early during the service life of the screen element 10, as the upper surface of the screen may wear.

The support frame, including the reinforcing members 50 and the bi-directional support members, allows the first members 101 and the second members 102 to be relatively thin, creating a large screening opening. The embodiments described herein have relatively large tensile strength and relatively small cross-sectional area. The manufacture of the support members and the thin first members 101 results in a larger percentage of open area of the screening member 10 and the entire 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.

According to an embodiment of the present disclosure, the shaker screen 10 includes a flexible molded polyurethane body 12 having substantially parallel side edge portions 14, 16 at opposite ends of the body 12 and a lower edge portion 18 substantially perpendicular to the side edge portions 14, 16, and an upper edge portion 20 substantially perpendicular to the side edge portions 14, 16 and opposite the lower edge portion 18. 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 forming the sieving openings 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 also include a third member 203 and a fourth member 204, the third member 203 and the fourth member 204 having a thickness that is 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 with a plurality of first members 101 therebetween. The fourth members 204 extend substantially parallel to each other and extend laterally between the lower edge portion 18 and the upper edge portion 20 with the plurality of second members 102 therebetween. The reinforcing member 50 may be integrally molded with the third member 203 and/or the fourth member 204, and additionally, the reinforcing 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 one another and extend transversely 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 the 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 extend transversely between the side edge portions 14, 16 with a plurality of third members 203 therebetween. The sixth members 306 extend substantially parallel to each other and extend laterally between the lower edge portion 18 and the upper edge portion 20 with the 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, the reinforcing member or rod may be integrally molded with the sixth member 306.

The screening elements according to this embodiment may have an open screening area of greater than 40% and mesh sizes ranging from about 0.375 mesh to about 400 mesh. The sieves tested with the above configuration include, for example, 43 mesh sieves, 140 mesh sieves, and 210 mesh sieves. Each of these screens had 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 frames created by the third, fourth fifth and sixth members 203, 204, 305, 306 and the reinforcing 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. In general, the grid units may be larger for sieves with larger screening openings and smaller for sieves with smaller screening openings. This principle is generally applicable to each of the example embodiments discussed herein. The grid element may also have a substantially rectangular shape or may have any other suitable shape for supporting the screening openings.

The use of polyurethane screening elements 10 described herein provides significant advantages over conventional wedge wire screens in that the screening side walls 601 are formed on the basket. The polyurethane screening elements 10 described herein have better resistance to abrasion, scuff, bending and chemical corrosion than metals, and therefore have a longer service life than wedge wire frames in the CIL process. Polyurethane also allows for the formation of significantly smaller screening openings than conventional wedge wire frames, thereby improving screening efficiency. The use of the polyurethane screening element 10 described herein provides a significantly larger screening area and significantly reduced clogging compared to conventional wedge wire screen baskets.

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

In the case of attaching the screen basket 1 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 slurry to be treated. The slurry level in the tank is higher than the liquid level in the screen basket 1. This arrangement allows the slurry to naturally flow through the screens of basket 1 in an effort to equalize the liquid levels in the slurry tank and basket 1. Blades outside the NKM units rotate inside the water tank around the periphery of the sieving side walls of the sieving basket 1. The outer vanes also help prevent particles from clogging the exterior of the polyurethane screen, such as by carbon and slurry. The pulsing and sweeping action reduces the likelihood of carbon and near standard size material covering the screening openings. Impeller blades located inside the screen, such as on a drive shaft, are used to keep the particles in suspension and drive the slurry upward toward the volute and wash tank.

During this process, the slurry flows upward through the interior of the screen basket 1. The carbon remains in the sieve. The slurry is present through a wash interface located above the polyurethane screen and volute interface.

During these processes, it can be seen that the continuous rotation of the inner and outer blades near the polyurethane screen, and the large amount of slurry flowing through the openings of the polyurethane screen, severely wears the screen. The arrangement of polyurethane screens and screen baskets described herein is designed to withstand significant wear and is significantly better than existing wire screen baskets in CIP and CIL processes.

Although the screen basket 1 has been described for use in a CIP or CIL process, 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. Basket 1500 includes a grid frame 1510 having a tubular shape (or having substantially cylindrical symmetry) relative to a longitudinal axis and having a plurality of openings 1513. Thus, the grid frame 1510 has a height and 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 25.4 cm) to about 73 inches (about 185.4 cm). In an exemplary embodiment, the height is about 80 inches (about 203.2 cm) and the diameter is about 50 inches (about 127 cm). It is noted that the present disclosure is not limited to such illustrative sizes of heights and/or diameters, and that other dimensions of the grid frame 1510 are contemplated. In addition, the grid frame 1510 is not limited to tubular or cylindrical symmetry, but may be configured in any shape suitable for sieving, particularly any shape suitable for carbon retention sieving as discussed herein. The grid frame 1510 may also be formed of any material that provides sufficient structure for the screening process and sufficient support for the screening cartridges to be attached to the grid frame 1510. For example, the grid 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 cartridges. In embodiments featuring a thermoplastic grill frame 1510, the grill frame 1510 may comprise a single injection molded piece. In other embodiments, the grid frame 1510 may be formed from separable pieces that are joined together to form the grid frame 1510.

In certain embodiments, the grid frame 1510 may be formed into a desired shape by bending the perforated sheet material onto itself about a longitudinal axis and engaging opposite edges of the perforated sheet material. The joined opposing edges may form a longitudinal seam 1515. In some embodiments, the perforated sheet 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 grid frame 1510 may be arranged in a square lattice, and each opening (or in some embodiments, at least some) of the plurality of openings 1513 may have a square shape. The plurality of openings 1513 may have other shapes than square, such as rectangular, oval, circular, etc. Furthermore, it is not required that the plurality of openings 1513 have a uniform shape throughout the grill frame 1510. For example, some embodiments may feature alternative rectangular openings 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 member 1511 and the transverse member 1512. The openings in such subsets may be referred to as internal openings. A second subset of the plurality of openings may 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 may 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 external openings.

The first annular portion 1512a and the second annular portion 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 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 1500 into a screen separator device (e.g., a NKM vertical sweep interstage device as shown in fig. 13 and 14). Additionally, the second flange 1530 may be fixed or otherwise attached to the second annular portion 1512b. 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 1500 into a screen separator device (e.g., an interstage device as shown in fig. 13 and 14 where NKMs are swept vertically), and/or securing a wiper assembly of a screen separator (not shown).

Referring to fig. 15, the basket 1500 may also include an opening near the second end of the grill frame 1510, near the second flange 1530. The tubing member 1540 may be assembled near the opening. The openings and tubing 1540 may form an outlet that may allow or otherwise facilitate the flow of slurry from the interior of the basket 1500 when slurry needs to be discharged when disassembled.

Similar to other screen baskets of the present disclosure, basket 1500 in combination with screen elements may be used in a separation process to separate specific particulate matter from a slurry or another type of liquid source. To this end, in one embodiment, the screen cartridge assembly may be mounted to basket 1500 where the screen cartridge assembly may allow or otherwise facilitate 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 screen cartridge assemblies 1610 in accordance with 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 1610c. Each of the screen cartridge assemblies 1610a, 1610b, 1610c may be mounted or otherwise secured to a respective set of grid members that at least partially define respective openings 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 1500 and then easily removed from the basket 1500 for maintenance or repair or may be permanently secured to the basket 1500. For continuous openings about the longitudinal axis of grid frame 1510, one set of grid members supporting a first one of screen cartridge assemblies 1610a and 16010b may have a common grid member with another set of grid members supporting a second one of screen cartridge assemblies 1610a and 16010 b. More specifically, in one example, first screen cartridge assembly 16010a may be gripped or otherwise attached to first and second longitudinal members of grid frame 1510. In addition, 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 grid frame 1510 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 greater detail in U.S. patent application Ser. No. 13/800,826, U.S. patent application Ser. No. 9,409,209, U.S. patent application Ser. No. 9,884,344, U.S. patent application Ser. No. 15/851,009, U.S. patent application Ser. No. 15/965,195, and cross references contained therein, the entirety of which is incorporated herein by reference. 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, or the like.

As shown in fig. 16B, screen cartridge assembly 1610a includes a housing 1630a and a screen assembly having 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 of screening units, a larger number of screening units results in a housing 1630a having a larger size, thus resulting in a larger screen cartridge assembly. Larger screen cartridge assemblies may be used in a grid frame having larger grid openings.

Housing 1630a includes a first opening configured to receive and/or fit screen assemblies within housing 1630 a. Housing 1630a also includes a second opening that allows the screening surfaces of the screen assemblies to be exposed to the exterior of grid frame 1510. The screening surface may be embodied as, or may comprise, for example, a substantially seamless and planar 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, or 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 ridge 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. Housing 1630a may be permanently mounted to grid frame 1510 using ridges 1650a and various portions of housing 1630a, or may be removably mounted to grid frame 1510 so that housing 1630a may be removed as needed for maintenance or repair.

Similarly, screen cartridge assembly 1610b includes a housing 1630b and a screen assembly with 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 screen assemblies within housing 1630 b. Housing 1630b also includes a second opening that allows the screening surfaces of the screen assemblies to be exposed to the exterior of grid frame 1510. The screening surface may be embodied as, or may comprise, for example, a substantially seamless and planar surface comprising a plurality of screening openings having, for example, a substantially uniform size and/or a substantially uniform shape. In addition, as shown in fig. 16C, housing 1630b further includes a ridge 1650b that extends from a first edge of housing 1630b proximate to the first opening to an opposite second edge of housing 1630 b. The ridge 16650b and portions of the housing 1630b may form corresponding notches that allow or otherwise facilitate mounting (e.g., clamping or gripping) of the housing 1630b to the grid frame 1510. With respect to the screen assemblies housed in housing 1630b, which are further shown in fig. 16C and 17, the screen assemblies 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 screen units 1640b may be mechanically bonded or otherwise secured together to form a screen assembly. To this end, each of the screen units 1640, e.g., as shown with reference to 1640b, may include one or more fasteners that may allow or otherwise facilitate securing a first one of the screen units (e.g., screen unit 1640 a) to a second screen unit (e.g., l640 b). Regardless of the mechanism used to connect the screen units 1640b, the individual screen elements of the screen units 1640 may form a screening surface that may be exposed to 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 Ser. No. 13/800,826, U.S. patent application Ser. No. 9,409,209, U.S. patent application Ser. No. 9,884,344, U.S. patent application Ser. No. 15/851,009, U.S. patent application Ser. No. 15/965,195, and cross-references included therein.

Similar to screen cartridge assemblies 1610a, 16010B, screen cartridge assembly 1610c also includes a housing 1603c and a screen assembly having three screen 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 screen assemblies within housing 1630 c. Housing 1630c also includes a second opening that allows or otherwise facilitates exposing a screening surface of a screen assembly to the exterior of grid frame 1510. The screening surface may be embodied as, or may comprise, for example, a substantially seamless and planar surface comprising a plurality of screening openings having, for example, a substantially uniform size and/or a substantially uniform shape. 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 ridge 1650c and corresponding portions of the housing 1630c form respective notches that allow or otherwise facilitate mounting (e.g., clamping or gripping) of the housing 1630c to the grid frame 1510. Figure 17 illustrates the mechanical coupling of screen cartridge assemblies 1610a and 1610b to the cross-grid members of grid frame 1510. As described above, ridge 1650a allows or otherwise facilitates mounting of screen cartridge assembly 16010a to grid frame 1510. Likewise, the ridges 1650b allow or otherwise facilitate mounting of the screen cartridge assembly 1610b to the grid frame 1510.

Screen cartridge assembly 1610a and screen cartridge assembly 1610b include respective screen assemblies. According to the embodiments described herein, the screen assemblies housed in screen cartridge assembly 1610a include three screen units 1640a. 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 as fewer or additional screen units, as well as screen assemblies having a different number of screen units.

In connection with the screen assemblies received in housing 1630C, as further shown in fig. 16C, each screen unit comprising a screen assembly includes a frame unit having screen elements secured to a surface of the frame unit. The screen units may be mechanically bonded or otherwise secured together to form a screen assembly. To this end, in one embodiment, each screening unit 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 connect 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 screen cartridge assemblies are shown in fig. 16A-16C and 17, the entire or substantially the entire grid frame 1510 of the screen basket 1600 may be covered for operation during the separation process. Thus, in the example embodiment, 264 screen cartridge assemblies may be installed into the corresponding 264 square openings 1513 in the embodiment of the grid frame 1510.

Fig. 18A shows a perspective view of an exemplary screen 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 a screen assembly having 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 screen assemblies within housing 1810. The housing also includes a first ridge 1820a and a second ridge 1820b. Each of the ridges 1820a and 1820b extends from near a first top edge of the housing 1810 to near an opposite second bottom edge of the housing 1810. In use, the arcuate shape of the housing 1810 allows the distance between the outer pusher blades of the screening device and the screen cartridge assembly to be substantially uniform, thereby reducing clogging and extending the life of the screen elements.

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

The screen units 1830 may be mechanically bonded or otherwise secured together to form a screen assembly. To this end, in one embodiment, each screen unit 1830 may include one or more fasteners that may allow or otherwise facilitate securing a first one of the screen units 1830 to a second one of the screen 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 screen cartridge assembly 1800. Housing 1810 also includes openings that allow 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 in cross-sectional views 1850 and 1870 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 portions 1854 may receive and/or retain screen assemblies formed by the screen units 1830. To this end, in some embodiments, the retainer frame portion 1854 includes an opening 1910 and interior sidewalls including sidewalls 1920, 1930, and 1940. The other interior sidewalls are not visible in the perspective view of fig. 19A. For example, as shown in 1950 in a cross-sectional view of housing 1810 shown in fig. 19B, a sidewall 1960 opposite sidewall 1920 and a sidewall 1980 opposite sidewall 1930 are also included in the inner sidewall of holder frame portion 1854. Sidewall 1920, which incorporates sidewalls 1930 and 1980, may define a first opening, and opposite sidewall 1960, which incorporates sidewalls 1930 and 1980, may define a second opening. The cross-sectional area of the second opening may be larger than the cross-sectional area of the first opening in order to mitigate the undesired reduction of the screening area. The smaller cross-section may provide greater mechanical stability to the 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 screen cartridge assembly including housing 1810. Particulate matter may be screened or separated by such screen assemblies. Specifically, particulate matter may be separated from slurry outside of a screen basket apparatus having a screen cartridge assembly including a screen assembly, and may flow to an interior region of the screen basket apparatus as desired or required for a screening application (e.g., CIL process, CIP process, ore treatment, water desalination, etc.).

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

In addition, with further reference to fig. 19A, the attachment frame portion 1852 includes an interior sidewall including sidewalls 1946 and 1948, and other sidewalls respectively opposite thereto. One of these opposing side walls may be collected in side view 1990 of fig. 19B. Specifically, sidewall 1992 is opposite sidewall 1946. The attachment frame portion 1852 further includes a ridge 1820a and a ridge 1820b. In one embodiment, the ridges 1820a and 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 one another on a grid frame 1510. The four screen assemblies may be inserted or otherwise assembled into the four housings 1810, respectively, to form four screen cartridges and assemble a screen basket for a variety of separation processes, such as the CIL process, the CIP process, water filtration, and desalination, among others.

Fig. 20A shows an example of a screen assembly 2000 in accordance with one or more embodiments of the present disclosure. Exemplary screen assemblies 2000 may be arranged or otherwise assembled within housing 1810 or any other housing described herein to form a screen cartridge assembly according to this disclosure. In keeping with the other screen assemblies disclosed herein, screen assembly 2000 includes three frame units, which may include two end frame units 1855 and a single intermediate frame unit 1857, with each of end frame units 1855 and intermediate 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 of the frame units 1855, 1857 (or in some embodiments, at least one) may be implemented as a single injection molded piece integrally formed by injection molding of a polymer. The frame units 1855, 1857 may be mechanically bonded or otherwise secured together to form the screen assembly 2000. To this end, in one embodiment, each of the frame units 1855, 1857 may include one or more fasteners that may allow or otherwise facilitate fastening a first one of the frame units 1855, 1857 to a second one of the frame units 1855, 1857. Regardless of the mechanism by which the joined frame units are utilized or relied upon, the joined frame units 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 further 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 a screening surface of the screen assembly 2000 and a screen cartridge 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. 20B, screen assemblies each (or in other embodiments, at least one) screen element 1860 may include four adjacent portions with a corresponding set of screen openings. Such portions may be separated by a support member (indicated by a broken line in plan view 20A). The present disclosure is not limited to screen elements having four portions and, in some embodiments, may be implemented with fewer or additional portions of screen openings.

Fig. 21A illustrates a perspective view of an intermediate frame unit 1857 in accordance with one or more embodiments of the present disclosure. The intermediate frame unit 1857 is elongate and includes longitudinal side members 2138 which are opposite and substantially parallel to one another. The mid-frame unit 1857 also includes lateral 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, the intermediate frame unit 1857 may include a fastening mechanism that allows or otherwise facilitates mechanically joining or securing the intermediate frame unit 1857 and another frame unit (end frame unit 1855 or intermediate frame unit 1857) together. In particular, in some embodiments, the fastening mechanisms may be assembled or otherwise formed on respective portions of the longitudinal side members 2138, while the lateral side members 2136 are devoid of fastening mechanisms. Referring to fig. 21A, in at least one of such embodiments, the fastening mechanism may be implemented 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) also having clips 2142 and clip holes 2140 may be mechanically joined or otherwise secured together along their respective longitudinal side members 2138. To this end, in one embodiment, the clips 2142 of the middle frame unit 1857 may be passed into the clip holes 2140 of another frame unit until the extending members of the clips 2142 extend beyond the clip holes 2140 and the longitudinal side members of the other frame units. As the clip 2142 is pushed into the clip aperture 2140, the extension members of the clip 2142 may be forced together until the gripping portion of each extension member extends beyond the longitudinal side members of the other frame unit, thereby allowing the gripping portion 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 the two individual frame units may be side-by-side and secured together (e.g., mechanically bonded). The frame units may be separated by applying a force to the extension members of the clip to move the extension members toward each other to allow the clip portions to pass through the clip apertures 2140. Although the fasteners described herein and shown in the drawings are clips and clip holes, the present disclosure is not limited in this respect and alternative fasteners and alternative forms of clips and/or holes may be used, including other mechanical devices, adhesives, and the like.

The middle frame unit 1857 further includes a longitudinal support member 2146 and a lateral support member 2148. Each longitudinal support member 2146 is substantially parallel to the longitudinal side members 2138 and substantially perpendicular to the transverse 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 mid-frame unit 1857. In addition, the longitudinal and transverse support members 2146, 2148 may provide mechanical stability to the screen elements secured to the mid-frame unit 1857.

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

In order to allow or otherwise facilitate the fixing of one or more screening elements to the intermediate frame unit 1857, attachment members 2144 and several adhesive arrangements are provided in the intermediate frame unit 1857. As shown in the side view 2190 of the mid-frame unit 1857 shown in fig. 21B, the first adhesive arrangement includes a plurality of fusion strips 2172 assembled (e.g., formed) on the surface of the longitudinal side members 2138. As shown in the top view 2150 of the intermediate 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 side view 2170 of intermediate frame unit 1857 in fig. 21B, the third adhesive arrangement comprises a plurality of fusion strips 2176. In some embodiments, the height of the weld 2176 may be less than the height of the weld 2172, and also less than the height of the weld 2152.

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

The end frame unit 1855 may have a similar structure to the middle frame unit 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 forming a seamless periphery. The first side portions 2220 are substantially parallel to each other, and each first side portion 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 a lateral side member (e.g., member 2136) of a frame unit 1855, 1857 (e.g., middle frame unit 1857) according to embodiments of the disclosure. As such, each of the side portions 2220 may include a cavity configured to receive or otherwise engage a weld bead on a surface of the lateral side member.

The screen element 1860 also includes several support members. More specifically, the screen element 1860 includes a support member 2230 and a support member 2238. Support member 2230 is substantially collinear with and substantially perpendicular to support member 2238. The support members 2238 are also substantially collinear. The screen element 1860 also includes a support member 2240 extending 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 corresponding support member of the frame units 1855, 1857 (e.g., the middle frame unit 1857). Accordingly, each of the support members 2230, 2238, and 2240 includes a cavity configured to receive or otherwise engage a weld bar on a respective surface of the support member of the frame unit.

The screen element 1860 also includes attachment holes 2224. One of the attachment holes 2224 is located substantially in the center of the screen element 1860. Other attachment holes 2224 are located at each corner of the seamless periphery of the screen element 1860. Regardless of the location in the screen element 1860, each (or, in some embodiments, at least one) of the attachment holes 2224 is configured to allow or otherwise facilitate the ability of the elongated attachment members 2144 (see, e.g., fig. 21A) to pass through the attachment holes 2224. In one or more such embodiments, the attachment holes 2224 may include tapered holes that may be filled when a portion of the elongated attachment members 2144 melt above 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, thereby allowing beads to form on the screening surface 2013 of the screen element 1860 when a portion of the elongated attachment members 2144 melt above such a screening surface, thereby securing the screen 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 intermediate frame unit 1857 (or another type of frame unit disclosed herein), and each of the four portions included in the screen element 1860 may cover four grid openings of the intermediate frame unit 1857, respectively.

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

Referring to fig. 22A and 22B (top and side views 2250, 2270 and 2290 of a screen element 1860 are shown), a plurality of openings may be arranged in segments with the screen openings in each segment being arranged in a grid. Each segment is at least partially defined by support members 2230, 2238, and 2240 of screen element 1860. In one embodiment, the screen openings adjacent the periphery of the screen element 1860 may be defined by longitudinal ribs parallel to the first side of the screen element 1860, transverse ribs perpendicular to the longitudinal ribs, and edge segments of the side of the 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 the major sides of the elongated slot and the transverse ribs define the minor sides of the elongated slot.

Fig. 22C is an enlarged top view of a portion of a screen 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 screen element includes surface elements 84 extending parallel to screen element ends 2220 and forming screen openings 86. The thickness T of the face element 84 may vary depending on the screening application and the configuration of the screening openings 86. In this example, the screen openings 86 are elongated slots having a length L and a width W, which may vary for the configuration selected. The thickness T of the surface element 84 may be about 43 μm to about 1000 μm (i.e., 0.0017 inch to 0.0394 inch) depending on the desired opening screening area and the width W of the screening openings 86.

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

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

TABLE 1

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Table 2 (below) shows a further exemplary configuration of the surface elements 84 and the screen openings 86. In the example, the surface element 84 has a fixed thickness t=0.014 inches. The screen openings 86 have a fixed length l=0.076 inches and a variable width W. It is contemplated that for a fixed number of screen openings 86, the percentage of opening area decreases with the width W of each screen opening 86. In this example, the percentage of open area varies from a minimum open area of 6.2% corresponding to a minimum width w=0.0017 inches to a maximum open area of 23.3% corresponding to a maximum width w=0.0071 inches.

TABLE 2

Number of meshes	W (inch)	T (inch)	L (inch)	% open area
					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 a further exemplary configuration of the surface elements 84 and the screening openings 86. Table 3 shows the effect of reducing the length L of the screen openings 86 and reducing the width T of the surface elements 84 so that the screen elements 1860 may include more screen elements. In this example, the surface element 84 has a fixed thickness t=0.007 inches. The screen openings 86 have a fixed length l=0.046 inches and a variable width W. The resulting percentage of open area varies from a minimum open area of 10.1% corresponding to a minimum width w=0.0017 inches to a maximum open area of 27.3% corresponding to a maximum width w=0.0071 inches. Thus, as can be seen by comparing the results of tables 3 and 2, by reducing T from 0.014 inch to 0.007 inch and by reducing L from 0.076 inch to 0.046 inch, the maximum opening area percentage increases from 23.3% to 27.3%. As described above, the increase in the percentage of maximum open area is due to the fact that as the size of the screen openings 86 and surface features decrease, more screen openings may be included on the screen element 1860.

TABLE 3 Table 3

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

TABLE 4 Table 4

Number of meshes	W (inch)	T (inch)	L (inch)	% open area
					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 assemblies 2300 having a curvature. In one of such embodiments, the fastening mechanism may include clips and clip apertures such that the 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 illustrate an alternative embodiment of a screen cartridge assembly 2400 for a screen basket of the present disclosure. The filter element assembly 2400 includes a removable housing having a top housing portion 2410 and a separate bottom housing portion 2411. The top and bottom housing portions 2410, 2411 each include an attachment mechanism 2440, which attachment mechanism 2440 is removably engageable with holes 2445 provided on the top and bottom housing portions 2410, 2411. In use, a screen assembly having screen unit 2430 may be assembled into either top housing portion 2410 or bottom housing portion 2411, and then the opposite housing portion may be assembled around the screen assembly by screen unit 2430. Attachment mechanism 2440 engages with aperture 2445 to securely fix the screen assembly and screen unit 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 the housing 1810 discussed herein, including an attachment frame portion, a retainer frame portion, and a ridge. As shown in the perspective view of bottom housing portion 2411 shown in fig. 25, attachment frame portion 2452 includes interior side walls and attachment ridges 2420a and 2420b that allow or otherwise facilitate mounting (e.g., clamping, gripping or otherwise engaging) of screen cartridge assembly 2410 to a grid frame of the present disclosure, such as grid frame 1510. Cage frame portion 2454 may receive and/or retain screen assemblies formed by screening units in a manner substantially similar to cage frame portion 1854 of housing 1800, discussed in more detail herein.

The top housing portion 2410 and the bottom housing portion 2411 may each be formed from a single injection molded piece 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 separating 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 Ser. No. 13/800,826, U.S. patent application Ser. No. 9,409,209, U.S. patent application Ser. No. 9,884,344, U.S. patent application Ser. No. 15/851,009, U.S. patent application Ser. No. 15/965,195, and the disclosures of the cross references included therein, the entire contents of which are incorporated herein by reference.

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 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 screening apparatus comprising:

a static vertical screen basket forming a plurality of grid openings;

a plurality of screens secured to the grid openings, the screens forming screening surfaces located outside of the screen basket;

wherein the screening surface is configured to separate large-sized material from small-sized material by allowing small-sized material to flow into the screen basket while preventing large-sized material from entering the screen basket,

wherein each screen has a synthetic screening surface with openings having a width in the range of 35 to 4000 micrometers, wherein each screen has a plurality of screening openings separated by surface elements, and wherein the thickness T of the surface elements is in the range of 43 to 1000 micrometers, and

wherein each synthetic screening surface is configured to separate carbon or resin from the slurry of leached carbon material, carbon material in slurry, or leached resin material as slurry fluid flows from the outside of the basket to the inside of the basket, thereby retaining carbon or resin on the synthetic screening surface.

2. The screening arrangement according to claim 1, wherein the screen is formed by injection moulding of a thermoplastic material.

3. The screening arrangement according to claim 2, wherein the screening openings have a length L in the first direction, the size of which is in the range of 300 μm to 4000 μm, and a width W in the second direction, the size of which is in the range of 35 μm to 4000 μm.

4. A screening device according to claim 3, wherein the thickness T of the surface elements in the second direction is in the range of 0.005 inch to 0.0283 inch in size, and wherein the screen has an open screening area of 16.4% to 31.4% of the total screening surface area.

5. The screening device of claim 4, wherein:

the screening openings have a length L of 0.1295 inches;

the width W of the screen openings is 0.0182 inches; and is also provided with

The surface element has a thickness T of 0.0283 inches.

6. The screening device of claim 4, wherein:

the screening openings have a length L of 0.1295 inches;

the width W of the screen openings is 0.0214 inches; and is also provided with

The surface element has a thickness T of 0.0252 inches.

7. The screening device of claim 4, wherein:

the screening openings have a length L of 0.1295 inches;

the width W of the screen openings is 0.0262 inches; and is also provided with

The surface element has a thickness T of 0.0241 inches.

8. The screening device of claim 1, wherein the synthetic screening surface is a thermoset material.

9. The screening device of claim 1, wherein the synthetic screening surface is a thermoplastic material.

10. The screening arrangement according to claim 1, wherein each of the screening openings has a length L in the first direction, the size of which is in the range of 300 μm to 4000 μm, and a width W in the second direction, the size of which is in the range of 35 μm to 4000 μm.

11. The screening device of claim 1, wherein the screening openings comprise a shape having an approximately rectangular, square, circular or oval shape.

12. The screening device of claim 1, wherein the synthetic screening surface comprises a polyurethane material.

13. The screening apparatus of claim 12, wherein the screen basket has a flat configuration.

14. The screening apparatus of claim 12, wherein the screen basket has a cylindrical configuration.

15. A method of filtering material using the screening device of any one of claims 1-14, the method comprising:

Introducing a screen assembly into a slurry stream in the screen apparatus, the screen apparatus having a tank containing leached carbon material, carbon material in slurry, or slurry of leached resin material, the slurry stream comprising resin or activated carbon, the screen assembly including a first side, a second side, and a synthetic screen surface on an outer surface of the screen assembly on the first side of the screen assembly, the synthetic screen surface having openings ranging from 35 microns to 4000 microns in width and 16.4% to 31.4% of the open screen area; and

the slurry stream passing through the screen assembly from the first side of the screen assembly to the second side of the screen assembly is filtered to remove resin or carbon from the slurry stream such that resin or carbon remains on the synthetic screening surface.

16. The method of claim 15, wherein the screen assembly comprises screen elements formed by injection molding.

17. The method of claim 15, wherein the synthetic screening surface is a thermoset material.

18. The method of claim 15, wherein the synthetic screening surface comprises a thermoplastic material.

19. The method of claim 15, wherein the synthetic screening surface comprises a polyurethane material.

20. The method of claim 15, wherein the screen assembly comprises a plurality of individual screen elements.

21. A screen basket apparatus for use in the method of filtering material of any one of claims 15-20, comprising:

a substantially vertical grille frame having a plurality of grille openings;

a screen secured to the grid openings, the screen forming a screening surface located outside the grid frame;

wherein the screening surface is configured to separate large-sized material from small-sized material by allowing small-sized material to flow into the screen basket while preventing large-sized material from entering the screen basket, and

wherein the screen has a synthetic screening surface forming screening openings on an outer surface of the screen basket, the screen basket being configured to prevent carbon or resin from entering an interior space of the screen basket when the screen basket is immersed in a slurry of leached carbon material, carbon material in slurry, or leached resin material, the screening openings having a width in the range of 35 microns to 4000 microns, the synthetic screening surface having an opening screening area of 16.4% to 31.4%.

22. The screen basket apparatus of claim 21 wherein the synthetic screening surface comprises a thermoset material.

23. The screen basket apparatus of claim 21 wherein the synthetic screening surface comprises a polyurethane material.

24. The screen basket apparatus of claim 21, wherein the screen openings have a length in the range of 0.44 mm to 60 mm and a width in the range of 0.044 mm to 4.0 mm.

25. The screen basket apparatus of claim 21 wherein the synthetic screening surface comprises a thermoplastic material.

26. The screen basket apparatus of claim 21, wherein a length of each screen opening is in a range of 300 to 4000 μιη, and a width of each screen opening is in a range of 35 to 4000 μιη.

27. The screen basket apparatus of claim 21 wherein the screen includes a plurality of individual screening members.

28. The screen basket apparatus of claim 27 wherein each of the individual screen members includes a molded polyurethane body having screen opening side portions and non-porous side portions,

wherein each of the screening opening side portions and non-porous side portions comprises a cast structural member configured to mechanically connect with a cross member or a longitudinal member of the grid frame, thereby attaching the individual screening members to the grid frame.

29. The screen basket apparatus of claim 27 wherein each screen member is a thermoplastic single injection molded piece.

30. The screen basket apparatus of claim 21 wherein the screen covers a plurality of the openings of the grid frame.

31. The screen basket apparatus of claim 21 wherein the grid frame has a cylindrical structure.

32. The screen basket apparatus of claim 21 wherein the screen is replaceable.

33. The screen basket apparatus of claim 32 wherein the screen is a component of a replaceable screen assembly.

34. The screen basket apparatus of claim 33, wherein the replaceable screen assembly includes a housing configured to retain the screen within the housing.

35. The screen basket apparatus of claim 34 wherein the housing includes a retainer frame portion configured to receive the screen.

36. The basket device of claim 35 wherein the housing further comprises an attachment frame portion seamlessly integrated with the retainer frame portion, the attachment frame portion comprising a first elongate ridge and a second elongate ridge opposite and substantially parallel to the first elongate ridge,

Wherein a first recess is formed between the first elongate ridge and the first portion of the attachment frame, and

wherein a second recess is formed between the second elongate ridge and the second portion of the attachment frame.

37. The screen basket apparatus of claim 36, wherein the first notch is configured to engage at least one of a first cross member or a first longitudinal member of the grid frame, and wherein the second notch is configured to engage at least one of a second cross member and a second longitudinal member of the grid frame.

38. The screen basket apparatus of claim 21 wherein the screen includes an exterior surface, an interior surface, the screen openings having a diverging width that increases with the distance of the exterior surface to the interior surface.

39. The screen basket apparatus of claim 38 wherein the screen openings have a trapezoidal shape.

40. The screen basket apparatus of claim 21, wherein surface elements of the synthetic screening surface separate the screening openings, and wherein a thickness T of the screening openings is between 43 μιη and 1000 μιη.