EA044418B1 - METHOD AND DEVICE FOR SORTING - Google Patents

Description

Link to related applications

This application claims priority to U.S. Provisional Application No. 16/151909, which is a continuation in part of U.S. Patent Application No. 16/001755, filed June 6, 2018, which claims priority to U.S. Patent No. 62/515,964, filed June 6, 2017, and U.S. Patent Application No. 62/615,302, filed Jan. 9, 2018, the contents of each of which are incorporated herein by reference, and the priority of each of which is claimed in this document.

Brief description of the figures

Various aspects and features of the present disclosure are described herein with reference to the drawings. Throughout the document, like numbers refer to like, but not necessarily the same or identical, elements.

In fig. 1 is a side view of a screen basket according to an exemplary embodiment of the present disclosure.

In fig. 2 is a top view of a screen basket according to an exemplary embodiment of the present disclosure.

In fig. 3 is a top side perspective view of a sieve basket according to an exemplary embodiment of the present disclosure.

In fig. 4 is a plan view of a polyurethane screen for use with a basket body according to an exemplary embodiment of the present disclosure.

In fig. 5 is a view of the polyurethane sieve of FIG. 4, opposite to the plan view of FIG. 4 according to an exemplary embodiment of the present disclosure.

In fig. 6 is a side view of a polyurethane screen for use with a basket body according to an exemplary embodiment of the present disclosure.

In fig. 7 is a partial plan view showing the attachment of screen elements to a basket frame according to an exemplary embodiment of the present disclosure.

In fig. 8 shows a section of the polyurethane screen shown in FIG. 4.

In fig. 8A is an enlarged view of the portion of the polyurethane screen shown in FIG. 8.

In fig. 9 is a fragmentary side cross-sectional view of a polyurethane screen according to an exemplary embodiment of the present disclosure.

In fig. 9A is an enlarged view of a portion of the fragmentary cross-sectional view shown in FIG. 9.

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

In fig. 11 is an enlarged fragmentary cross-sectional view similar to that of FIG. 10, but showing the first elements without reinforcing elements according to an exemplary embodiment of the present disclosure.

In fig. 12 is an exploded isometric view of a portion of a polyurethane screen according to an exemplary embodiment of the present disclosure having reinforcing elements integral with the first and second elements.

In fig. 13 is an exploded view of the use of a sieve basket according to an exemplary embodiment of the present disclosure in an embodiment of a sieve sorting device.

In fig. 14 is a perspective side cross-sectional view of an exemplary embodiment of using a sieve basket according to an exemplary embodiment of the present disclosure in an embodiment of a sieve sorting device.

In fig. 15 is a perspective view of an example basket body according to an illustrative embodiment of the disclosure.

In fig. 16A is a perspective view of an exemplary screen basket that contains a plurality of screening cartridge assemblies attached to the basket body according to an example embodiment of the present disclosure.

In fig. 16B is a fragmentary perspective view of the screen basket shown in FIG. 16A showing a plurality of sorting cartridge assemblies according to an exemplary embodiment of the present disclosure.

In fig. 16C is a fragmentary perspective view of the interior of the sieve basket shown in FIG. 16A showing a plurality of sorting cartridge assemblies according to an exemplary embodiment of the present disclosure.

In fig. 17 is a fragmentary cross-sectional view of exemplary sorting cartridge assemblies mounted on a grid frame according to an exemplary embodiment of the present disclosure.

In fig. 18A is a perspective view of an example of a sorting cartridge assembly according to an illustrative embodiment of the present disclosure.

In fig. 18B is a cross-sectional and side view of the exemplary sorting cartridge assembly shown in FIG. 18A. In the views, illustrative dimensions are shown in inches. The opening is not limited to these dimensions, and other dimensions may be envisaged.

In fig. 19A is a perspective view of an illustrative sorting cartridge assembly housing according to an illustrative embodiment of the present disclosure.

In fig. 19B is a cross-sectional and side view of the illustrative housing shown in FIG. 19A. In the views, illustrative dimensions are shown in inches. The opening is not limited to these dimensions, and other dimensions may be envisaged.

In fig. 19C illustrates an example of a plurality of bodies attached to a lattice frame of a basket body according to an exemplary embodiment of the present disclosure.

In fig. 20A illustrates an example of a sorting unit element according to an exemplary embodiment of the present disclosure.

In fig. 20B is a cross-sectional and side view of an exemplary sorting unit element shown in FIG. 20A. In the views, illustrative dimensions are shown in inches. The opening is not limited to these dimensions, and other dimensions may be envisaged.

In fig. 21A is a perspective view of an example of a sorting unit frame block according to an illustrative embodiment of the present disclosure.

In fig. 21B is a top and side view of the exemplary frame block shown in FIG. 21A.

In fig. 22A shows an example of a screening unit screen element.

according to an exemplary embodiment of the present disclosure.

In fig. 22B is a top and side view of the exemplary screen element shown in FIG. 22A.

In fig. 22C is an enlarged top view of a portion of a screen element according to an illustrative embodiment of the present disclosure.

In fig. 23A illustrates another example of a sorting unit element according to an exemplary embodiment of the present disclosure.

In fig. 23B is a side view of the exemplary sorting unit element shown in FIG. 23A.

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

In fig. 25 is an example of a lower portion of the cartridge screen element housing shown in FIG. 25.

Detailed Disclosure of the Present Invention

The present disclosure relates to filtration devices and methods, and specifically to the use of improved sieve baskets for use in methods and systems for sorption of metals from metal-containing ores. Embodiments of the present disclosure can be used with, among others, carbon in pulp (CIP), carbon in leach (CIL), and resin in leach (RIL) systems. CIL and CIP systems are, for example, two countercurrent methods of adsorption of leached gold from a slurry stream onto activated carbon. In such CIL and CIP processes, a plurality of adsorption reservoirs are arranged in series. The pulp flows continuously from the first reservoir in this sequence to the last reservoir. At the same time, coal is pumped countercurrently from the last tank in the sequence to the first tank. The CIL and CIP processes differ in the extent to which gold is leached before adsorption onto the carbon. For example, in a CIL operation, carbon is added to the leach tanks and the leach and adsorption reactions occur simultaneously. In contrast, in the CIP process, most of the leachable gold is leached before the first adsorption step.

A description of a general method for recovering gold from gold ore using a combined cyanidation and adsorption treatment can be found in U.S. Patent No. 4,188,208. Although embodiments of the present disclosure are generally discussed with reference to gold or coal, embodiments of the present disclosure can also be applied to methods for recovering silver, iron, nickel and other metals from suitable ores. The recovery of any metal from the mined ore is within the scope of this disclosure.

A description of existing metal screen baskets and methods for using them in the CIP processes described above can be found in US Patent No. 5,238,117. The method described in US Pat. No. 5,238,117 has generally become known in the art as NKM interstage vertical purification screening methods, and the used therein, sieve baskets have generally become known in the art as NKM sieve baskets. Typically, these NKM screen baskets contain a metal support frame having a wedge-shaped wide mesh wrapped around its peripheral side walls. Wedge wire mesh is used to filter metal-rich pulp materials. The sieve basket is attached to the NKM sorting device, and the lower part of this sorting device

- 2 044418 of an NKM device containing an attached NKM sieve basket is immersed in a tank containing coal-in-pulp material. The impellers on the NKM screen ensure that the slurry in the tank passes through the wedge-shaped wire mesh and into the interior of the NKM screen baskets. However, wedge wire mesh has a very low open sorting area, resulting in inefficient sorting. Low open sorting area also leads to clogging. The clogging, in turn, causes increased volumes of slurry to pass through the unclogged areas of the wedge wire mesh, which increases the rate of wear of the mesh. In addition, the individual wires that form the wedge-shaped wire meshes tend to fracture or break over time due to forces generated during the sorting process, such as cleaning by internal and external push blades.

In illustrative embodiments of the present disclosure, an improved screen basket arrangement for sorting material is provided. The device includes a support frame having a substantially closed bottom and an open top, and a substantially cylindrical side wall support portion extending between the bottom and top of the support frame. The support frame may be metal, for example stainless steel. The polyurethane screen sidewall extends around and rests on the sidewall support area. The polyurethane sieve side wall contains a polyurethane sieve with a large open area. In some embodiments, a polyurethane screen sidewall substantially surrounds the sidewall support portion between the closed bottom and the open top, thereby providing maximum screening area. The polyurethane screen side wall can be attached to the outer periphery of the side wall support portion.

The polyurethane screen sidewall can be formed from a plurality of individual polyurethane screen elements. These individual polyurethane screen elements can be aligned next to each other to create an overall continuous screening area in the screen sidewall. In one example, the plurality of individual polyurethane screen elements may comprise eight individual polyurethane screen elements. In such embodiments, the eight individual polyurethane screen elements may be arranged such that four screen elements are located on the lower half of the support frame and four screen elements are located on the upper half of the support frame.

In some embodiments, the substantially closed bottom may have a central opening that receives the drive shaft of the NKM device.

In some embodiments, the large open area polyurethane screen element comprises a flexible molded polyurethane body; sieve holes in the housing; a set of first substantially parallel flexible members defining opposite first sides of the screen openings; a set of second substantially parallel flexible members defining second opposite sides of the screen openings, the first members being substantially perpendicular to the second members; a set of third substantially parallel elements having a plurality of first elements between them; a set of fourth substantially parallel elements having a plurality of second elements between them; lateral edge portions substantially parallel on opposite sides of the housing, between which third elements extend therein; and the first end portion and the second end portion are substantially parallel at opposite ends of the housing between which the fourth members extend therein, the end portions being substantially perpendicular to the edge portions. The screen openings in the flexible molded polyurethane body of the polyurethane screen element may range from about 0.044 mm to about 4000 mm between the internal surfaces of the first elements, and from about 0.044 mm to about 60,000 mm between the internal surfaces of the second elements.

The polyurethane screen element may also include reinforcing elements integrally molded within at least one of the first and third elements and at least one of the second and fourth elements. In some embodiments, the reinforcing elements formed integrally within the first elements may have a substantially uniform thickness ranging from about 0.006 inches to about 0.015 inches. The reinforcing elements molded integrally with the second elements may have a substantially uniform thickness ranging from about 0.015 inches to about 0.040 inches. The reinforcing elements can be made, for example, in the form of rods, which can be molded as a single unit with the elements. The reinforcing elements may also be in the form of, for example, aramid fibers, which are at least one of spun and woven multistrand yarns, with fibers having a linear density of from about 55 denier to about 2840 denier.

The lateral edge portions of the polyurethane screen element may be configured to be used for attaching the screen element to a support frame. A plurality of enlarged polyurethane ribs may be formed integrally on the outer surface of the polyurethane screen body, the ribs being substantially vertical relative to the support portion

- 3 044418 side walls. Each of the plurality of ribs may extend substantially from the top to the bottom of the polyurethane screen element.

In additional embodiments of the present disclosure, a basket body may be provided that includes a tubular or substantially cylindrical lattice frame with a plurality of openings. The plurality of openings in the lattice frame may be arranged in a square lattice pattern, and each (or in some embodiments at least some) of the plurality of openings may be square in shape. In an illustrative embodiment, the plurality of holes may include 264 square holes. A subset of multiple holes may be formed by longitudinal members and transverse members. A second subset of a plurality of openings may be formed by the longitudinal members and transverse segments of the first annular lattice frame section, and similarly, a third subset of the plurality of openings may be formed by the longitudinal members and transverse segments of the second annular lattice frame section.

The basket body may have flanges at the top and bottom of the body. The top flange and holes may provide or otherwise facilitate installation of a plate or other type of cover onto the flange. In additional or other embodiments, the flange and holes may provide or otherwise facilitate installation of the basket body into a screen screening machine (eg, an NKM Interstage Vertical Cleaner).

The basket body can be used in a separation process to separate certain solids from a slurry or other type of fluid source. To this end, in one embodiment, sorting cartridge assemblies may be installed in the basket body, wherein the sorting cartridge assemblies may provide or otherwise facilitate the separation of certain solids from the sludge. Each of the sorting cartridge assemblies may be mounted or otherwise attached to a corresponding group of grid elements that define, at least in part, a corresponding opening of the grid frame. For openings in a row relative to the longitudinal axis of the lattice frame, a group of lattice elements that support a first of the sorting cartridge assemblies may share a lattice element with another group of lattice elements that support a second of the sorting cartridge assemblies.

In some embodiments, each of a plurality of sorting cartridge assemblies mounted or attached to a lattice frame includes a sorting unit and a housing (or other type of container) configured to receive and hold the sorting unit. In some embodiments, the housing may be formed as a single injection molded part formed integrally by injection molding a polyurethane, thermoset polymer, or other type of polymer. Exemplary embodiments of an injection molded part and a method for producing an injection molded part are discussed in more detail in U.S. Patent Application Disclosure No. 13/800826, U.S. Patent No. 9,409,209, U.S. Patent No. 9884344, U.S. Patent Application No. 15/851009, Application U.S. Patent No. 15/965,195 and the references contained therein, which are hereby incorporated by reference in their entirety.

In some embodiments, the screening unit has three separate screen units. The housing contains a first opening configured to receive and/or accommodate a sorting unit inside the housing, and a second opening that allows the sorting surface of the sorting unit to be exposed to the outside of the lattice frame. The housing also includes ridges that extend from a first edge of the housing, near the first opening, to an opposite second edge of the housing. The ridges and corresponding portions of the housing form corresponding grooves that permit or otherwise facilitate installation (eg, gripping or snapping) of the housing onto the lattice frame.

To carry out the separation process, the entire or substantially all of the screen basket lattice frame may surround the sorting cartridge assemblies. Accordingly, in an illustrative embodiment, 264 sorting cartridge assemblies may be installed in corresponding 264 square holes in the lattice frame.

In addition, the housing may include a frame mounting section and a frame holding section. The holding section of the frame may receive and/or hold a sorting unit formed by the sieve units. The frame mounting section may include a set of ridges that define corresponding grooves that in turn provide or otherwise facilitate attachment (eg, by snapping, clamping, or otherwise engaging) of the sorting cartridge assembly to the lattice frame.

The sieve cartridges of the present disclosure may be of any suitable shape for attachment to the screen frame of the basket body. For example, and without limitation, screen cartridges may be square, or rectangular, or round, or any other shape. Although exemplary embodiments may have screen cartridges having a shape that is substantially aligned with the screen openings of the screen frame (i.e., a square screen cartridge on a screen frame with square screen holes), different shaped screen cartridges may be attached to the holes gratings of different shapes. Likewise, the lattice frame of the basket body can be of any shape suitable for sorting.

The screen elements and screen cartridges of the embodiments discussed herein resist wear, abrasion, bending, and chemicals better than metal and thus tend to last longer than wedge wire frames in CIL processes. The screen elements discussed herein also provide significantly smaller screen openings than conventional wedge wire frames, which in turn improves screening efficiency. The use of screen elements as described herein provides significantly larger screening areas and significantly reduces screen clogging compared to conventional wedge-shaped wire screen baskets. When used, the screen elements and screen cartridges that are described herein also provide a substantially constant distance between the outer pusher blades of the screen and the screen cartridge assembly, thereby reducing clogging and extending the life of the screen elements.

Next, with reference to the embodiment shown in FIG. 1-5, the screen basket 1 of the present disclosure includes a basket frame structure 510 that has a large open area polyurethane screen 600 attached thereto.

As shown in FIG. 1, basket frame 510 generally has a cylindrical configuration, although other shapes may be used. Preferably, the basket frame 510 may be formed from 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 defining a vertical support portion extending between the upper and lower ends 511, 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 basket frame support 510 may be formed from a plurality of vertical support members 530 and a plurality of horizontal support members 550. In the embodiment shown in FIG. 3, includes four primary support members 531 spaced around the periphery of the frame 510, along with a plurality of additional support members 542 spaced between the primary support members 531. Together, the primary and secondary support members 531, 542 connect the upper and lower ends 511, 515 of the frame 510. in a spaced configuration. The horizontal support members 550 may be a plurality of concentric rings or curved sections that are connected end to end to form a plurality of concentric rings spaced apart throughout the basket frame 510.

As shown in FIG. 3, each of the vertical support members 531 may include an internal post member 532. The inner strut member 532 may, in turn, include through holes 534. Horizontal support members 550 extend through the holes 534, thereby holding the horizontal support members 550 stacked on top of each other and in a spaced apart configuration.

As shown in the top view of FIG. 2, the upper end 511 of the frame 510 has an opening to allow use for receiving and processing materials within the screen basket 1. The lower end 515 of the frame 510 has a substantially solid or closed bottom 516 for holding materials in the screen basket 1 during processing. The substantially closed bottom 516 may have a central opening 517 for use in an operating configuration with processing machine shafts, as discussed in more detail below.

Embodiments of the disclosure may include a large open area polyurethane screen 600 attached to the periphery of a frame 510 thereby forming a screen basket 1 having an open top, a substantially solid or closed bottom 516, and a polyurethane screen sidewall 601.

The polyurethane screen 600 may be provided as separate, smaller screen elements 10 due to possible size limitations during the molding process of the polyurethane screen 600. For example, as in the embodiment shown in FIG. 1, polyurethane screen 600 may have a plurality of individual screen elements 10. Each screen element 10 is attached to a vertical support frame 510.

In fig. 4-6 show features of an illustrative embodiment of a screen element 10 configured to form a polyurethane screen sidewall 601 of a screen basket 1. FIG. 4-5 show the outer and inner sides of an embodiment of the screen element 10, respectively, while FIG. 6 is a side view of an embodiment of screen element 10. Screen element 10 may comprise polyurethane screens described in more detail in the following patents and patent publications that share a common assignment with the present disclosure and are incorporated herein by reference: US Pat. No. 8,584,866; US Patent No. 9010539; US Patent No. 9375756; US Patent No. 9403192; publication of application for US patent No. 5 044418 No. 2015/0197827A1; and publication of U.S. Patent Application No.

2016/0303611A1.

As shown in FIG. 4-7, in an embodiment of the present disclosure, a screen element 10 may be provided with a molded polyurethane body 12 having non-perforated side edge portions 14, 16. Each of the side edge portions 14, 16 may have an integral side ridge portion 29 for use for compaction. adjacent screen elements 10 to each other and for attaching the screen elements 10 to the basket frame 510, as shown in FIG. 7. Each side edge portion 14, 16 may include a molded structural member for use in reinforcing the side ridge portion 29. The side edge portions 14, 16 may also be formed without molded structural members or may contain other structural members. The side ridge portions 29 may be of any suitable shape for attachment to the basket frame 510. In an illustrative embodiment, the side ridge portions 29 may comprise a formed member, such as a metal member, bent into a desired shape, such as a U-shaped member, an L-shaped member, a C-shaped member, and the like. The formed element can be attached to the polyurethane body by heating, pressing, molding, mechanical, chemical and/or any other suitable method or device.

The body 12 of the screen element 10 also includes a lower edge portion 18 and an upper edge portion 20, which, in combination with the side edge portions 14, 16, form the outer boundary of the screen element 10. In some embodiments, the side ridge portion 29 may extend the entire length between an upper edge portion 20 and a lower edge portion 18.

Housing 12 further includes an outer surface 22 and an inner surface 24. In FIG. 4 shows the outer surface 22 of the housing 12 when the screen element 10 is attached to the basket frame 510, as shown, for example, in FIG. 1, and in Fig. 5 shows the interior surface 24 of the housing 12 when the screen element is attached to the basket frame 510, as shown, for example, in FIG. 1. The housing 12 includes first members 101 and second members 102 defining screen openings 26, as shown in detail in FIG. 8 and 8A. In some embodiments, the first elements 101 and the second elements 102 may be configured to contain reinforcing elements 50, as discussed in more detail below. As shown in the side view of FIG. 6, screen element 10 may further include vertical ribs 28 on an outer surface 22 of screen element 10. However, in some embodiments of the present disclosure, screen element 10 may not include vertical ribs 28.

Housing 12 may further include third elements 203 and fourth elements 204. Third elements 203 and fourth elements 204, and vertical ribs 28, if present, may also include reinforcing elements 50, discussed in more detail below. However, in some embodiments of the present disclosure, third elements 203, fourth elements 204, and vertical ribs 28 may not include reinforcing elements 50. Third elements 203 and fourth elements 204 are generally configured to provide support for screen openings 26 defined by the first and second elements 101 , 102.

In fig. 8 shows part of an embodiment of the screen element 10, and FIG. 8A is an enlarged view of a portion of FIG. 8. As shown in the detail view of FIG. 8A, the first and second members 101, 102 form a first integrally molded lattice structure 100 that defines the screen openings 26. The third and fourth elements 203, 204 may form a second integrally molded lattice structure 200, and the fifth and sixth elements 305 and 306, respectively, may in turn form a third integrally molded lattice structure 300.

Reinforcing elements 50 may be incorporated into desired elements of screen element 10. Reinforcing elements 50 provide stability to screen element 10 by preventing warping and/or extrusion defects of side edges 14, 16. In an illustrative embodiment, reinforcing elements 50 may be incorporated (e.g., by molding as a whole) into suitable elements. The reinforcing elements 50 may be made of plastic, metal, polymer, or any other suitable material with the desired structural properties. For example, the reinforcing elements 50 may be in the form of rods that are integrally molded with the screen elements. The reinforcing elements 50 may also be in the form of aramid fibers that are at least one of spun multi-strands and woven multi-strands such that the fibers act as wicks for absorbing polyurethane molded around them, thereby providing a strong bond with him. Spun or woven multistrand fibers can have a linear density of from about 55 denier to about 2840 denier, and preferably can have a linear density of about 1500 denier. When an aramid fiber is used in embodiments of the present disclosure, it may be a set of aramid fibers marketed by DuPont Company under the trade name KEVLAR®. The reinforcing elements 50 may also be at least one of the aramid fibers marketed by Teijin Company under the trade names TWARON, SULFRON, TEIJINCONEX and TECHNORA. Flexibility

- 6044418 aramid fibers provide a flexible reinforcing system for molded polyurethane that can return to its original molded shape after the necessary bending and bending that occurs during handling and installation. In some embodiments, the reinforcing members 50 may be tensioned before polyurethane is molded around them.

Again with reference to the exemplary embodiment shown in FIG. 4-5, and a detail view shown in FIG. 8, lattice structures 200 and 300 comprise bi-directionally integrally molded elements that form support latticework within the elements. Due to the properties of the reinforcing elements 50 and the configuration of the bidirectional lattice structure, the elements can be relatively small in size and thus provide an increased open sorting area. The lattice structures provide screen strength and support for the 26 holes during vibration loading and significantly increase the open screening area.

As shown in detail in FIG. 8A, the first elements 101 may extend laterally between the side edge portions 14, 16 substantially parallel to each other. The second elements 102 may extend laterally between the lower edge portion 18 and the upper edge portion 20 substantially parallel to each other and substantially perpendicular to the first elements 101. In some embodiments, the second elements 102 may have a thickness greater than the thickness of the first elements 101 to provide additional structural support for holes 26 sieve.

As mentioned above and as shown in the isometric view of FIG. 12 in an exploded view, the first elements 101 and/or the second elements 102 may include reinforcing elements 50 and may or may not be supported by additional support elements or lattice support structures. For example, as shown in FIG. 9, which is a fragmentary cross-sectional view of the housing 12 of the screen element 10, the housing 12 has first and second members 101, 102 with bidirectional reinforcing members 50 integrally molded therewith. The reinforcing members 50, integrally molded with the first members 101, have a thickness ranging from about 0.006 inches to about 0.015 inches. The reinforcing members 50, integrally molded with the second members 102 (not shown), have a thickness ranging from about 0.015 inches to about 0.040 inches. Such configurations may be preferred for screening applications requiring large opening screens.

In embodiments of the present disclosure, any of the first, second, third and fourth elements 101, 102, 203, 204, as well as the ribs 28, may contain reinforcing elements 50, which may be contained in either all or part of the first, second, third and fourth elements 101, 102, 203, 204 and elements 28 ribs.

As shown in FIG. 8 and in detail in Fig. 8A, the screen openings 26 may be elongated, with a greater length along the sides and between their ends than the width. The screen openings 26 may have a width from about 0.044 mm to about 4.0 mm, with the width being the extent between the inner surfaces of adjacent first members 101. The screen openings 26 may have a length from about 0.44 mm to about 60 mm, with the length being the extent between the inner surfaces of adjacent second elements 102. In addition, the screen openings 26 can have a variety of different shapes. For example, the screen openings 26 may have a rectangular shape, or a square shape, or a circular shape, or any other shape that may be formed by the first and second elements 101, 102. The overall dimensions of the screen element 10 may be approximately 1.2 meters by 1. 6 meters, or can have any other required size. It is understood that all dimensions given herein are provided as an example only and not as a limitation.

Briefly referring to FIG. 10 and fig. 11, the screen openings 26 may radiate downwardly between the outer surface 22 and the inner surface 24, with the first elements 101 having the shape of substantially inverted trapezoids. This overall trapezoidal shape of the first elements 101 prevents clogging of the screen element 10 and generally the polyurethane screen 600. The first elements 101 may include reinforcing elements 50 molded integrally therewith, as shown in FIG. 10, or may optionally not include reinforcing elements 50 integrally molded therewith, as shown in FIG. eleven.

As shown in detail in FIG. 8A, the third and fourth members 203, 204 may be thicker than the first and second members 101, 102. The increased thickness of the third and fourth members 203, 204 may provide additional structural support to the first and second members 101, 102. As shown in the exemplary embodiment of FIG. . 8 and 8A, the third elements 203 may extend laterally between the lateral edge portions 14, 16 substantially parallel to each other and may have a plurality of first elements 101 disposed therebetween. The fourth elements 204 may extend laterally between the lower edge portion 18 and the upper edge portion 20 substantially parallel to each other and may have a plurality of second elements 102 disposed therebetween. The reinforcing members 50 may be integrally molded with the third and fourth members 203, 204. The third and fourth members 203, 204 may be made to a minimum thickness by incorporating the reinforcing members 50 while maintaining

- 7 044418 at the same time the necessary structural support for the screen openings 26 formed by the first and second elements 101, 102 in the vibratory screening application. The bi-directional support system provided by the third and fourth elements 203, 204, and the additional support of the reinforcing elements 50 incorporated therein, if present, significantly reduces the thickness of the support elements and provides increased screen open area and overall screen efficiency.

The housing 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 ribs 28 may be thicker than the third and fourth members 203, 204 and may have a portion extending from the inner surface 24 of the housing 12. As shown in FIG. 2, there may also be ribs 28 extending from the outer surface 522 of the housing 12 and thereby providing vertical support along the outer screen side wall 601. The greater thickness and arrangement of the ribs 28 provide the first and second elements 101, 102 with additional structural support.

The ribs 28 may extend laterally between the lower edge portion 18 and the upper edge portion 20 substantially parallel to each other and may have a plurality of fourth elements 204 therebetween. Additionally and alternatively, the ribs 28 may extend laterally between the lateral edge portions 14, 16 substantially parallel to each other and may have a plurality of third elements 203 therebetween. The ribs 28 may have reinforcing members 50 integrally molded with them. Ribs 28 may be provided to provide additional support for the screen openings 26 and may be made to a minimum thickness through the inclusion of reinforcing members 50 while still providing the necessary structural support to support the screen openings 26 in a vibratory screening application. As well as the third and fourth elements 203, 204, the provision of a rib support system 28 significantly reduces the thickness of the support elements and provides increased screen open area and overall screen efficiency.

Various configurations of reinforcing elements 50 may be provided in the support rib elements 28 to add stability to the screen element 10. The reinforcing elements 50 provided in the support rib elements 28 may be aramid fiber (or individual strands thereof), natural fiber, or other material having relatively high tensile strength with relatively small cross-sectional areas.

Each element of the screen element 10 capable of containing such reinforcing elements 50 may contain zero, one or a plurality of reinforcing elements 50, and the reinforcing elements 50 used therein may be of different sizes and materials. Reinforcing elements 50 may be located in the lower halves of the elements so as not to be exposed relatively early in the life of the screen element 10 as the upper surface of the screen may wear out.

The inclusion of the reinforcing elements 50 as well as the support frame of the bidirectional support elements ensures that the first elements 101 as well as the second elements 102 are relatively thin, creating large screen openings. The embodiments that are described herein have relatively high tensile strength with relatively small cross-sectional areas. The creation of the support elements and thin first elements 101 results in the screen element 10 and the overall screen 600 having a higher percentage of open area, which in turn increases the throughput of the system. Open screening areas according to the embodiments described herein can range, for example, from about 40% to about 46% screen.

According to an embodiment of the present disclosure, the vibrating screen 10 includes a flexible molded polyurethane body 12 having substantially parallel side edge portions 14, 16 at opposite ends of the body 12, as well as a lower edge portion 18 substantially perpendicular to the side edge portions 14, 16, and an upper an edge portion 20 substantially perpendicular to the side edge portions 14, 16 and opposite the lower edge portion 18. The polyurethane body 12 further includes an outer surface 22 and an inner surface 24. First and second elements 101, 102 defining sorting holes 26 are shown. First elements 101 extend between the side edge portions 14, 16, and second members 102 extend between the lower and upper edge portions 18, 20. The housing 12 may also include third and fourth members 203, 204, the third and fourth members 203, 204 being thicker than the first members. and second elements 101, 102. Third elements 203 extend substantially parallel to each other and extend laterally between the lateral edge portions 14, 16, and have a plurality of first elements 101 disposed therebetween. The fourth elements 204 extend substantially parallel to each other and extend laterally between the lower and upper edge portions 18, 20, and have a plurality of second elements 102 disposed therebetween. The reinforcing members 50 may be integrally molded with the third and/or fourth members 203, 204, and further, the reinforcing members or rods may be integrally molded with the fourth members 204. The body 12 also includes ribs 28. The ribs 28 may be substantially parallel to each other and extend laterally between the side edge portions 14, 16. The ribs 28 may also be substantially parallel to each other and extend laterally between the lower and upper edge portions 18, 20. The ribs 28 are thicker than the third and fourth members 203, 204 and may include reinforcing members 50 molded integrally therewith. The housing 12 may further have fifth and sixth elements 305, 306. The fifth elements 305 extend substantially parallel to each other and extend laterally between the side edge portions 14, 16, and have a plurality of third elements 203 disposed therebetween. The sixth elements 306 extend substantially parallel to each other and extend laterally between the lower and upper edge portions 18, 20, and have a plurality of fourth elements 204 disposed therebetween. The reinforcing members 50 may be integrally molded with the fifth and/or sixth members 305, 306, and further, the reinforcing members or rods may be integrally molded with the sixth members 306.

The screen elements of this embodiment may have open screen areas greater than 40% and mesh sizes ranging from about 0.375 mesh to about 400 mesh. For example, test screens having the above configurations had a 43 mesh screen size, a 140 mesh screen size, and a 210 mesh screen size. Each of these screens had open screening areas ranging from about 40% to about 46%. Such large sorting areas for such relatively small cell sizes are achieved by the relatively strong and thin lattice frame created by the third, fourth, fifth and sixth elements 203, 204, 305, 306, and by the reinforcing elements molded integrally therewith. .

In the above embodiments and examples, the size of each lattice block formed by the intersection of the third and fourth elements 203, 204 is approximately 1 inch by 1 inch. In general, screen blocks can be larger for screens with larger openings, and screen blocks can be smaller for screens with smaller holes. This principle may be generally applicable to each exemplary embodiment discussed herein. The screen blocks may also be generally rectangular in shape or may have any other suitable shape to support the screen openings.

The use of polyurethane screen elements 10, as described herein, to form the screen sidewall 601 on the basket frame has significant advantages over conventional wedge wire screens. The polyurethane screen elements 10 that are described herein resist wear, abrasion, bending and chemical attack better than metal and thus tend to last longer than wedge wire frames in CIL processes. Polyurethane also produces significantly smaller screen openings than conventional wedge wire frames, which in turn improves screening efficiency. The use of polyurethane screen elements 10, which are described herein, provides significantly larger screening areas and significantly reduces screen clogging compared to conventional wedge-shaped wire screen baskets.

In operation, the screen basket 1 described herein can be used with known CIP and CIL devices and methods, such as those described in US Pat. No. 5,238,117. For example, as shown in FIG. 13-14, the sieve basket 1 is attached under the spiral part of the interstage vertical cleaning device NKM. The drive shaft of the NKM device passes from the top to the bottom of the sieve basket 1 and through the central hole in the closed bottom of the sieve basket 1. A gearbox and motor are located above the helix to drive the drive shaft. The boundary surface of the trough is located above the polyurethane screen and the boundary surface of the spiral to receive the flow of discharged pulp.

With the sieve basket 1 attached to the NKM device, the lower part of the NKM device containing the sieve basket 1 is inserted and suspended over a large adsorption tank containing the slurry slurry to be processed. The slurry level in the tank exceeds the fluid level in Sieve Basket 1. This configuration allows the slurry to naturally flow through the screen of Sieve Basket 1 in an attempt to equalize the fluid levels in the slurry tank and Sieve Basket 1. The blades on the outside of the NKM unit rotate inside the tank around the outside periphery of the sieve side wall of the sieve basket 1. The outer blades also help prevent particles from clogging the outside of the polyurethane sieve, such as coal and slurry. The pulse and cleaning action reduces the likelihood of coal and similar sized material clogging the screen holes. Impeller blades located on the inside of the screen, such as on the drive shaft, serve to hold the particles in suspension and move the slurry up the spiral and trough.

During the process, the pulp flows upward through the inside of sieve basket 1. Coal is retained in the sieve. The pulp enters through the boundary surface of the trough, located above the polyurethane sieve and the boundary surface of the spiral.

In these methods, it can be seen that the continuous rotation of the inner and outer blades in close proximity to the polyurethane screen, coupled with the flow of large volumes of pulp through the openings of the polyurethane screen, exposes the screen to significant wear and tear. Polyurethane

- 9 044418 The screens and screen basket configuration described herein are designed to withstand significant wear and tear and are significantly superior to existing wire screen baskets in CIP and CIL processes.

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

In fig. 15 is a perspective view of an illustrative basket body 1500 according to a further embodiment of the disclosure. The basket body 1500 includes a lattice frame 1510 that is tubular (or which has substantially cylindrical symmetry) about a longitudinal axis and has a plurality of openings 1513. Accordingly, the lattice frame 1510 has a height and a diameter. By way of illustration, the height may range from about 23 inches (about 58 cm) to about 122 inches (about 310 cm). As another illustration, the diameter may range from about 10 inches (about 25.4 cm) to about 73 inches (about 185.4 cm). In an illustrative embodiment, the height is approximately 80 inches (approximately 203.2 cm) and the diameter is approximately 50 inches (approximately 127 cm). It should be noted that the disclosure is not limited to such illustrative heights and/or diameters, and other dimensions of the lattice frame 1510 may be envisaged. Moreover, the lattice frame 1510 is not limited to tubular or cylindrical symmetry, but may have any configuration suitable for sorting, specifically for coal retention screening as discussed in this document. The grid frame 1510 may also be formed from any material that provides a satisfactory design for the sorting process and sufficient support for the sorting cartridges that will be attached to the grid frame 1510. For example, the grid frame 1510 may be formed from a metal or metal alloy, such as stainless steel. steel, or may be a thermoplastic material sufficient to support the sorting cartridges. In embodiments including a thermoplastic lattice frame 1510, the lattice frame 1510 may comprise a single injection molded part. In other embodiments, the trellis frame 1510 may be formed from detachable parts joined together to form the trellis frame 1510.

In some embodiments, the lattice frame 1510 can be formed into a desired shape by folding the perforated sheet toward itself about a longitudinal axis and joining opposite edges of the perforated sheet. The joined opposing edges may form a longitudinal seam 1515. In some embodiments, the perforated sheet may be formed from a metal or metal alloy (eg, stainless steel), and the opposing edges may be joined by welding. In other embodiments, the perforated sheet may be formed from 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 lattice frame 1510 may be arranged in a square lattice, and each (or in some embodiments at least some) of the plurality of openings 1513 may be square in shape. The plurality of holes 1513 may have shapes other than square, such as a rectangular shape, an oval shape, a circular shape, and so on. Additionally, the plurality of openings 1513 do not need to have a consistent shape throughout the lattice frame 1510. For example, in some embodiments, there may be alternating rectangular openings of different sizes to form an overall lattice frame 1510. In an illustrative embodiment, the plurality of openings 1513 may include 264 square holes. A subset of multiple openings may be formed by longitudinal members 1511 and transverse members 1512. The openings in such a subset may be referred to as internal openings. A second subset of multiple openings may be formed by longitudinal members 1511 and transverse segments of a first annular section 1512a of the lattice frame 1510. Likewise, a third subset of multiple openings may be formed by longitudinal members 1511 and transverse segments of a second annular section 1512b of the lattice frame 1510. The second subset and third a subset of the holes can be called external holes.

The first annular section 1512a and the second annular section 1512b may define or otherwise constitute respective opposing end portions of the lattice frame 1510 along the longitudinal axis. A flange 1520 may be attached or otherwise attached to the end of the first annular section 1512a. Flange 1520 may include a plurality of first openings 1525. Flange 1520 and first openings 1525 may permit or otherwise facilitate installation of a plate or other type of cover onto flange 1520. In addition or in other embodiments, flange 1520 and first openings 1525 may permit or otherwise facilitate installing the basket body 1500 into a screen sorting machine (eg, an NKM Interstage Vertical Cleaner as shown in FIG. 13 and FIG. 14). In addition, the second flange 1530 can be attached or otherwise attached to the second annular section 1512b. The second flange 1530 may contain

- 10 044418 a plurality of second openings 1535. The flange 1530 and second openings 1535 may enable or otherwise facilitate installation of the basket body 1500 into a screen screening machine (e.g., an NKM interstage vertical purifier as shown in FIGS. 13 and 14), and/ or attaching an external cleaning assembly to a sieve screening machine (not shown).

As shown in FIG. 15, the basket body 1500 may also include an opening in close proximity to the second end of the lattice frame 1510 near the second flange 1530. The pipe member 1540 may be mounted in close proximity to the opening. The opening and pipe member 1540 may define an outlet that may allow or otherwise facilitate the release of sludge from the inner basket body 1500 when it needs to be removed during disposal.

Similar to other screen baskets according to this disclosure, the basket body 1500 in combination with sorting elements can be used in a separation process to separate certain solids from a slurry or other type of fluid source. To this end, in one embodiment, sorting cartridge assemblies may be installed in the basket body 1500, wherein the sorting cartridge assemblies may provide or otherwise facilitate the separation of certain solids from the sludge. Specifically, by way of illustration, FIG. 16A is a perspective view of an example screen basket 1600 that contains a plurality of screening cartridge assemblies 1610 according to one or more embodiments of the disclosure. The plurality of sorting cartridge assemblies includes a first sorting cartridge assembly 1610a, a second sorting cartridge assembly 1610b, and a third sorting cartridge assembly 1610c. Each of the sorting cartridge assemblies 1610a, 1610b, 1610c may be mounted or otherwise attached to a corresponding group of grid elements that define, at least in part, a corresponding opening of the grid frame 1510. The sorting cartridge assemblies 1610 may be removable such that the sorting cartridge assemblies can be installed in the basket body 1500 and subsequently easily removed from the basket body 1500 for maintenance or repair, or may be permanently attached to the basket body 1500. For openings in a row relative to the longitudinal axis of the lattice frame 1510, a group of lattice elements that support a first of sorting cartridge assemblies 1610a and 1610b may share a lattice element with another group of lattice elements that support a second of sorting cartridge assemblies 1610a and 1610b. More specifically, in one example, the first sorting cartridge assembly 1610a may be clamped or otherwise attached to the first longitudinal member and the second longitudinal member of the lattice frame 1510. Additionally, the second sorting unit 1610b may be clamped or otherwise attached to the second longitudinal member and the third longitudinal member .

In some embodiments, each of a plurality of sorting cartridge assemblies mounted or attached to the lattice frame 1510 includes a sorting unit and a housing (or other type of container) configured to receive and hold the sorting unit. In some embodiments, the housing may be formed as a single injection molded part formed integrally by injection molding a polyurethane, thermoset polymer, or other type of polymer. Exemplary embodiments of an injection molded part and a method for producing an injection molded part are discussed in more detail in U.S. Patent Application Disclosure No. 13/800826, U.S. Patent No. 9,409,209, U.S. Patent No. 9884344, U.S. Patent Application No. 15/851009, Application U.S. Patent No. 15/965,195 and the references contained therein, which are hereby incorporated by reference in their entirety. The housing and sorting unit they contain can be of any shape and design suitable for installation on a lattice frame. In some embodiments, the housing and sorting assembly may be substantially rectangular. In other embodiments, the housing and sorting unit may be square in shape, or may be round in shape, or may be triangular in shape, and so on.

As shown in FIG. 16B, the screening cartridge assembly 1610a includes a housing 1630a and a screening assembly having three screen units 1640a. It should be noted that the disclosure is not limited to three screen units, and in some embodiments, fewer or additional screen units may be provided. For a given screen block size, more screen blocks results in a larger housing 1630a, which results in a larger screen cartridge assembly. Large sorting cartridge assemblies can be used in grid frames that have large grid openings.

Housing 1630a includes a first opening configured to receive and/or accommodate a sorting unit within housing 1630a. The housing 1630a also includes a second opening that allows the sorting surface of the sorting unit to be exposed from the outside of the lattice frame 1510. The sorting surface may be configured as or may comprise, for example, a substantially seamless and flat surface containing a plurality of sorting openings having, for example, substantially uniform size and/or substantially uniform shape. The plurality of sorting holes can be rectangular, square, round, etc.

- 11 044418 combination and the like. Moreover, as shown in FIG. 16C, housing 1630 also includes ridges 1650a that extend from a first edge of housing 1630a, near the first opening, to an opposing second edge of housing 1630a. The ridges 1650a and corresponding portions of the housing 1630a define corresponding grooves that provide or otherwise facilitate installation (e.g., gripping or snapping) of the housing 1630a onto the lattice frame 1510. The housing 1630a may be permanently mounted to the lattice frame 1510 through the use of the ridges 1650a and the corresponding portions. housing 1630a, or may be removably mounted on a lattice frame 1510 such that housing 1630a can be removed for maintenance or repair as needed.

Likewise, the screening cartridge assembly 1610b includes a housing 1630b and a screening assembly having three screen units 1640b. As mentioned, the disclosure is not limited to three screen units, and in some embodiments, fewer or additional screen units may be provided. Housing 1630b also includes a first opening configured to receive and/or accommodate a sorting unit within housing 1630b. The housing 1630b also includes a second opening that allows the sorting surface of the sorting unit to be exposed from the outside of the lattice frame 1510. The sorting surface may be configured as or may comprise, for example, a substantially seamless and flat surface containing a plurality of sorting openings having, for example, substantially uniform size and/or substantially uniform shape. Moreover, as shown in FIG. 16C, housing 1630b further includes ridges 1650b that extend from a first edge of housing 1630b, near the first openings, to an opposing second edge of housing 1630b. The ridges 1650b and corresponding portions of the housing 1630b may define corresponding grooves that allow or otherwise facilitate installation (eg, gripping or snapping) of the housing 1630b onto the lattice frame 1510. With respect to the sorting unit contained in the housing 1630b, as further illustrated in FIG. 16C and FIG. 17, each of the screen units 1640b includes a frame unit having one or more screen elements attached to a surface of the frame unit, and the screen units 1640b may be mechanically joined or otherwise secured together to form a screening unit. To this end, each of the screen units 1640, such as those illustrated with reference to 1640b, may include one or more fastening devices that may enable or otherwise facilitate attachment of the first of the screen units (e.g., screen unit 1640a) to the second of the screen units ( for example 1640b). Regardless of the connection mechanism of the screen units 1640b, the corresponding screen elements of the screen units 1640 may form a screening surface that may be exposed to slurry on the exterior of the screen frame 1510.

In some embodiments, each (or in other embodiments, at least one) of the screen elements may be configured as a single injection molded piece formed integrally by injection molding a thermoplastic material. Exemplary thermoplastic materials and methods for making exemplary thermoplastic materials used as screen elements according to the present disclosure are discussed in detail in U.S. Patent Application No. 13/800,826, U.S. Patent No. 9,409,209, U.S. Patent No. 9,884,344, U.S. Patent Application No. 15 /851009, US Patent Application No. 15/965195 and the references contained therein, which are incorporated herein by reference in their entirety.

The sorting cartridge assembly 1610c, such as the sorting cartridge assemblies 1610a, 1610b, also includes a housing 1630c and a sorting assembly having three screen units (not shown in FIG. 16B). As mentioned, the disclosure is not limited to three screen units, and in some embodiments, fewer or additional screen units may be provided. Housing 1630c also includes a first opening configured to receive and/or accommodate a sorting unit within housing 1630c. The housing 1630c also includes a second opening that provides or otherwise facilitates exposure of the sorting surface of the sorting unit to the outside of the lattice frame 1510. The sorting surface may be configured as or may comprise, for example, a substantially seamless and flat surface containing a plurality of sorting openings having , for example, a substantially uniform size and/or a substantially uniform shape. Moreover, as shown in FIG. 16C, housing 1630c further includes ridges 1650c that extend from a first edge of housing 1630c, near the first opening, to an opposing second edge of housing 1630c. The ridges 1650c and corresponding portions of the housing 1630c define corresponding grooves that permit or otherwise facilitate installation (eg, gripping or snapping) of the housing 1630c onto the lattice frame 1510. FIG. 17 illustrates the mechanical connection of the sorting cartridge assembly 1610a and the sorting cartridge assembly 1610b to the lattice cross members of the lattice frame 1510. As mentioned, the ridges 1650a provide or otherwise facilitate installation of the sorting cartridge assembly 1610a on the lattice frame 1510. Also, the ridges 1650b provide or otherwise facilitate installing the sorting cartridge assembly 1610b on the grid frame 1510.

The sorting cartridge assembly 1610a and the sorting cartridge assembly 1610b include

- 12 044418 existing sieve units. The sorting unit contained in the cartridge assembly 1610a includes three screen units 1640a according to the embodiments described herein. Another sorting unit contained in the cartridge assembly 1610b also contains three screen units according to the embodiments described herein. As mentioned, the disclosure is not limited to screen units having three screen units, and in some embodiments, fewer or additional screen units may be provided, and screen units having a different number of screen units may be provided.

In combination with the sorting unit contained in housing 1630c, as further illustrated in FIG. 16C, each of the screen units that constitute the screening unit includes a frame block having a screen element attached to a surface of the frame block. The screen units can be mechanically joined or otherwise secured together to form a screening unit. To this end, in an embodiment, each of the screen units may include one or more fastening devices that may enable or otherwise facilitate attachment of the first of the screen units to the second of the screen units. Regardless of the mechanism for connecting the screen units, corresponding screen elements of the screen units 1640 may form a screening surface that can be exposed from the outside of the screen frame 1510.

It should be noted that although FIG. 16A-16C and FIGS. 17 shows three sorting cartridge assemblies, all or substantially all of the screen frame 1510 of the screen basket 1600 may be used to operate the separation process. Accordingly, in an illustrative embodiment, 264 sorting cartridge assemblies may be installed in corresponding 264 square holes 1513 in the lattice frame embodiment 1510.

In fig. 18A is a perspective view of an example sorting cartridge assembly 1800 according to one or more embodiments of the present disclosure. An exemplary screening cartridge assembly 1800 includes a housing 1810 and a screening assembly having three screen units 1830. As mentioned, the disclosure is not limited to three screen units, and in some embodiments, fewer or additional screen units may be provided. Housing 1810 has a generally arcuate shape and includes a first opening configured to receive and/or accommodate a sorting assembly within housing 1810. The housing also includes a first ridge 1820a and a second ridge 1820b. Ridge 1820a and ridge 1820b each extend from an area near the first upper edge of housing 1810 to an area near the opposite second lower edge of housing 1810. In use, the arcuate shape of housing 1810 provides a substantially constant distance between the outer push vanes of the sorting device and the sorting cartridge assembly, reducing This causes clogging and extends the service life of the sieve elements.

Similar to other sorting cartridge assemblies according to this disclosure, as shown in the cross-sectional top view 1850 of the sorting cartridge assembly 1800 shown in FIG. 18B, each of the screen units 1830 may include two end frame blocks 1855 and one middle frame block 1857, wherein each of the two end frame blocks 1855 and one middle frame block 1857 has a screen element 1860 attached to a corresponding surface of the frame blocks.

The screen units 1830 may be mechanically joined or otherwise secured together to form a screening unit. To this end, in an embodiment, each of the screen units 1830 may include one or more fastening devices that may enable or otherwise facilitate attachment of the first of the screen units 1830 to the second of the screen units 1830. Regardless of the mechanism for connecting the screen units, the respective screen elements of the screen units 1830 may form a sorting surface of the sorting cartridge assembly 1800 . Housing 1810 also includes an opening that allows at least a portion of the sorting surface to be exposed, as shown in side view 1890 of sorting cartridge assembly 1800 in FIG. 18B.

As shown in cross-sectional views 1850 and 1870 of FIGS. 18B, housing 1810 may include a fastening frame section 1852 and a holding frame section 1854. The frame fastening section 1852 and the frame holding section 1854 are also shown in the perspective view of the housing 1810 shown in FIG. 19A. The frame holding section 1854 may receive and/or hold a sorting unit formed by the screen units 1830. To this end, in some embodiments, the frame holding section 1854 includes an opening 1910 and internal side walls, including a side wall 1920, a side wall 1930, and a side wall 1940. Other inner side walls are not visible in the perspective view of FIG. 19A. For example, as shown in cross-sectional view 1950 of housing 1810 shown in FIG. 19B, a side wall 1960 opposite the side wall 1920 and a side wall 1980 opposite the side wall 1930 are also included in the inner side walls of the frame retaining section 1854. Side wall 1920, in combination with side walls 1930 and 1980, may define a first opening, and opposite side wall 1960, in combination with side walls 1930 and 1980, may define a second opening. The second hole may have a cross-sectional area greater than the cross-sectional area of the first hole in order to reduce undesirable reduction in sorting area. A smaller cross section can provide

- 13 044418 provides greater mechanical stability to the sorting assembly located within the housing 1810. The first opening and the second opening may allow solids to pass from outside to the interior of the sorting cartridge assembly containing the housing 1810. The solids may be sorted or otherwise separated by such a sorting assembly. Specifically, the solids may be separated from the slurry on the outside of a screen basket device having a screening cartridge assembly containing a screen assembly, and may pass into the interior of the screen basket device as provided or required for screening applications (e.g., in a CIL process, in the CIP method, ore processing, water demineralization, etc.).

As further illustrated in cross-sectional views 1870 and 1970 in FIG. 18B and FIG. 19B, accordingly, the frame holding section 1854 may include a ridge 1872 near an opening configured to receive a sorting unit and a ridge 1874 near the base of the housing 1810.

Additionally, with further reference to FIG. 19A, the frame mounting section 1852 includes inner side walls, including a side wall 1946 and a side wall 1948, as well as other side walls, respectively, opposite them. One of these opposing side walls can be seen in side view 1990 of FIG. 19B. Specifically, the side wall 1992 is the opposite side wall 1946. The frame mounting section 1852 also includes a tongue 1820a and a tongue 1820b. In one embodiment, tongue 1820a and tongue 1820b and corresponding portions of frame mounting section 1852 define corresponding grooves 1856. Such grooves, as mentioned, may allow or otherwise facilitate installation (e.g., snapping, clamping, or otherwise engaging) of the sorting cartridge assembly 1800 onto a lattice frame according to this disclosure, such as the lattice frame 1510 disclosed previously. By way of illustration, FIG. 19C shows four housings 1810 mounted adjacent to each other on a grid frame 1510. The corresponding four sorting units may be inserted or otherwise inserted into the four housings 1810 to form four sorting cartridges and assemble a screen basket for a variety of separation processes, such as CIL, CIP method, water filtration and demineralization and the like.

In fig. 20A illustrates an example of a sorting facility 2000 according to one or more embodiments of the disclosure. An exemplary sorting assembly 2000 may be positioned or otherwise mounted within housing 1810 or any other housing described herein to form a sorting cartridge assembly according to this disclosure. In accordance with other sorting units disclosed herein, the sorting unit 2000 includes three frame blocks, which may contain two end frame blocks 1855 and one middle frame block 1857, wherein each of the end frame blocks 1855 and the middle frame block 1857 includes attached to screen elements 1860. 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 units 1860 may be attached to each of three frame units 1855, 1857. In some embodiments, fewer or additional frame blocks 1855, 1857 and/or screen elements 1860 may be provided. Each (or in some embodiments, at least one) of frame blocks 1855, 1857 may be formed as a single injection molded part. , formed as a single whole by injection molding of a polymer. The frame blocks 1855, 1857 may be mechanically joined or otherwise secured together to form a sorting unit 2000. To this end, in an embodiment, each of the frame blocks 1855, 1857 may include one or more fastening devices that may provide or otherwise facilitate attachment of the first of frame blocks 1855, 1857 to the second of the frame blocks 1855, 1857. Regardless of the mechanism used or otherwise involved to connect the frame blocks, the connected frame blocks 1855, 1857 form a first segmented edge element and an opposing second segmented edge element (not visible in Fig. 20A). The connected frame blocks 1855, 1857 also include a first monolithic edge element and a second monolithic edge element (not visible in FIG. 20A) corresponding to the edge elements of the outer frame blocks 1855, 1857, respectively.

Screen elements 1860 attached to each of the frame blocks 1855, 1857 may form a sorting surface of the sorting unit 2000 and the sorting cartridge assembly that includes the sorting unit 2000. The sorting surface may be substantially seamless, as shown in cross-sectional views 2050 and 2070 sorting unit 2000 in FIG. 20B. In some embodiments, as shown in side view 2090 of sorting station 2000 in FIG. 20B, each (or in other embodiments, at least one) of the screen elements 1860 may include four adjacent sections having corresponding groups of sorting holes. Such sections may be separated by support elements (represented by dotted lines in plan view 2090). The disclosure is not limited to screen elements having four sections, and in some embodiments, fewer or additional sections may be provided having sorting holes.

- 14 044418

In fig. 21A is a perspective view of a middle frame block 1857 according to one or more embodiments of the disclosure. The middle frame block 1857 is elongated and includes longitudinal side members 2138 that are opposed and substantially parallel to each other. The middle frame block 1857 also includes transverse side members 2136 that are opposed and substantially parallel to each other. Each transverse side member 2136 is substantially perpendicular to the longitudinal side members 2138. As mentioned, the middle frame block 1857 may include fastening mechanisms that provide or otherwise facilitate mechanical connection or otherwise fastening together of the middle frame block 1857 and another frame block (or end frame block 1855 or middle frame block 1857). Specifically, in some embodiments, fastening mechanisms may be assembled or otherwise formed at respective portions of the longitudinal side members 2138, wherein the transverse side members 2136 do not include fastening mechanisms. As shown in FIG. 21A, in at least one such embodiment, the fastening mechanisms may be configured as or may include latches 2142 and latch holes 2140. The middle frame block 1857 and another frame block (eg, end frame block 1855), also having latches 2142 and latch holes 2140, can be mechanically connected or otherwise secured together along their respective longitudinal side members 2138. To this end, in one embodiment the latch 2142 of the middle frame block 1857 can be inserted into the latch hole 2140 of the other frame block until the flared elements of the latch 2142 extend beyond the latch hole 2140 and the longitudinal side member of the other frame block. When the latch 2142 is pushed into the latch hole 2140, the flared elements of the latch 2142 can be pressed together until the latch portion of each flared element is located outside the longitudinal side member of the other framing unit, allowing the latch portions to engage the inside of the longitudinal side member of the other framing unit. block. When the latch portions engage the latch hole 2140, the longitudinal side members of two independent frame blocks can be positioned side by side and can be fastened together (eg, mechanically joined). The frame blocks can be separated by applying a force to the flared latch members so that the flared members move toward each other to allow the latch portions to exit the latch hole 2140. Although the fasteners described herein and shown in the figures are latches and latch holes, the disclosure is not limited thereto, and alternative fasteners and alternative forms of latch and/or holes may be used, having other mechanical features, adhesives, etc. .

The middle frame block 1857 also includes longitudinal support members 2146 and transverse support members 2148. Each of the longitudinal support members 2146 is substantially parallel to the longitudinal side members 2138 and is substantially perpendicular to the transverse side members 2136. Each transverse support member 2148 is substantially parallel to the transverse ones. side members 2136 and is substantially perpendicular to the longitudinal support members 2146. The longitudinal support members 2146 and the transverse support members 2148 define, at least in part, a plurality of grid openings within the middle frame block 1857. In addition, the longitudinal support members 2146 and the transverse support members 2148 can provide mechanical stability to the screen element that is attached to the middle frame block 1857.

The middle frame block 1857 may also include second transverse support members 2145 substantially perpendicular to the longitudinal side members 2138. As shown in FIG. 21A and side view 2170 of FIG. 21B, the second lateral support members 2145 may be distributed across the screen openings in the middle frame block 1857. The second lateral support members 2145 may provide mechanical stability to the screen element that is attached to the middle frame block 1857.

To enable or otherwise facilitate attachment of one or more screen elements to the middle frame block 1857, the middle frame block 1857 contains fastening elements 2144 and several adhesive devices. As shown in side view 2190 of the middle frame block 1857 shown in FIG. 21B, the first adhesive device includes a plurality of fusible pads 2172 mounted (eg, formed) on the surface of the longitudinal side members 2138. As shown in a top view 2150 of the middle frame block 1857 of FIG. 21B, the second adhesive device includes a plurality of fusible pads 2152 mounted (eg, formed) on the surface of the transverse side members 2136 and the transverse support members 2148. As shown in a side view 2170 of the middle frame block 1857 of FIG. 21B, the third adhesive device includes a plurality of fusible pads 2176. In some embodiments, the fusible pads 2176 may have a height less than the height of the fusible pads 2172, and also less than the height of the fusible pads 2152.

In some embodiments, fasteners 2144 may provide or otherwise facilitate alignment of the laser welded screen element with the midframe block

- 15 044418

1857 or other type of frame block disclosed herein. 2144 fasteners and/or various fusible strips can be fused during laser welding.

The end frame blocks 1855 may have a design similar to that of the middle frame block 1857. The attachment mechanisms in the end frame block 1855 may be contained in a single longitudinal side member of the frame block 1855.

In some embodiments, the screen element may be configured as or include a screen element 1860, as shown in FIG. 22A. Screen element 1860 includes first side portions 2220 and second side portions 2222 that form a seamless periphery. The first side portions 2220 are substantially parallel to each other, and each of the first side portions 2220 is substantially perpendicular to the second side portions 2222. Likewise, the second side portions 2222 are substantially parallel to each other, and each of the second side portions 2222 is substantially perpendicular to the first side portions 2220. Each side portions 2220 are configured to support and attach to transverse side members (eg, members 2136) of the frame block 1855, 1857 (eg, middle frame block 1857) according to embodiments of this disclosure. Accordingly, each of the side portions 2220 may include cavities configured to receive or otherwise engage fusible strips on the surface of the transverse side members. Likewise, the side portions 2222 are configured to support the longitudinal side members of the frame block 1855, 1857 (eg, frame block 1857) according to this disclosure. Thus, each of the side portions 2222 includes cavities configured to receive or otherwise engage fusible strips on a corresponding surface of the longitudinal side members.

Screen element 1860 also includes several support elements. More specifically, screen element 1860 includes support elements 2230 and support elements 2238. Support elements 2230 are substantially aligned and substantially perpendicular to support elements 2238. Support elements 2238 are also substantially aligned. The screen element 1860 also includes support elements 2240 that extend from the first of the side portions 2222 to the second of the second side portions 2222. Each of the support elements 2230, 2238 and 2240 is configured to support or be attached to the corresponding support elements of the frame block 1855, 1857, for example, to the middle frame block 1857. Thus, each of the support elements 2230, 2238 and 2240 includes cavities configured to receive or otherwise engage fusible strips on a corresponding surface of the frame block support elements.

Screen element 1860 further includes mounting holes 2224. One of the mounting holes 2224 is located substantially in the center of screen element 1860. Other mounting holes 2224 are located at corresponding corners of the seamless periphery of screen element 1860. Regardless of position in screen element 1860, each (or in some embodiments implementation, at least one) of the fastening holes 2224 is configured to allow or otherwise facilitate passage of an extended fastening element 2144 (for example, see Fig. 21A) through the fastening hole 2224. In one or more such embodiments, the fastening holes 2224 may include a tapered a channel that can be filled by melting a portion of the elongated fastener 2144 over the screening surface of the screen element 1860, attaching the screen element 1860 to the middle frame block 1857 or other type of frame block disclosed herein. In other embodiments, the fastening holes 2224 may be provided without a tapered channel, allowing the formation of a ball on the screening surface 2013 of the screen element 1860 by melting a portion of the elongated fastening element 2144 over such screening surface, attaching the screen element 1860 to the middle frame block 1857 or other type of frame block disclosed in this document. The screen element 1860 may span a half portion of the middle frame block 1857 (or other type of frame block disclosed herein), and each of the four sections contained in the screen element 1860 may correspondingly span the four grid openings of the middle frame block 1857.

The 2213 sorting surface has many sorting holes. Each (or in some embodiments, at least some) of the plurality of sorting holes may be elongated and may have a specific length L and a specific width W (for example, see FIG. 22C and related description below), having corresponding values based on Screening applications (e.g., CIL process, CIP process, ore processing, water demineralization, etc.) where the 1860 screen element is used.

As shown in FIG. 22A and FIG. 22B (representing top and side views 2250, 2270, and 2290 of screen element 1860), a plurality of holes may be arranged in sections, with the sorting holes in the section located in the grid. Each of the sections is formed at least in part by support members 2230, 2238, and 2240 of screen member 1860. In one embodiment, sorting holes that are adjacent to the periphery of screen member 1860 may be formed by longitudinal bars parallel to the first side portions of screen member 1860. , transverse bars perpendicular to the longitudinal bars, and segments of the edges of the side portions of the screen element 1860. In addition, the screen holes that are located in the interior of the section can be formed by longitudinal bars and transverse bars. The longitudinal bars form the larger side of the elongated holes, and the transverse bars form the smaller side of the elongated holes.

In fig. 22C is an enlarged top view of a portion of a screen element according to an illustrative embodiment of the present disclosure. In fig. 22C illustrates features common to different screens according to the disclosure, such as screen 1860 shown in FIG. 22A and 22B. As shown in FIG. 22C, the screen element includes surface elements 84 extending parallel to the end portions 2220 of the screen element and defining sorting holes 86. The surface elements 84 have a thickness T, which may vary depending on the screening application and the configuration of the sorting holes 86. In this example, the sorting holes 86 are elongated slots having a length L and a width W, which can be changed for the selected configuration. The thickness T of the surface elements 84 can range from about 43 μm to about 1000 μm (i.e., from 0.0017 inch to 0.0394 inch) depending on the desired open sorting area and the width W of sorting openings 86.

In some embodiments, the plurality of sorting holes may have a substantially uniform length L with a value ranging from about 300 μm to 4000 μm (ie, 0.0118 inch to 0.1575 inch). In addition, the plurality of sorting holes may have a substantially uniform width W ranging from about 35 µm to about 4000 µm (ie, 0.0014 inch to 0.1575 inch). By way of illustration, in some embodiments, the width W may be approximately one of 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 an illustrative embodiment, the plurality of sorting holes may have a substantially uniform length L of approximately 500 microns (ie, 0.0197 inches).

In table 1 shows several illustrative configurations of surface features 84 and sorting holes 86.

Table 1

Example No. L(inch) W (inches) T (inches) 1 0.1295 0.0182 0.0283 2 0.1295 0.0214 0.0252 3 0.1295 0.0262 0.0241

In table 2 provides additional illustrative configurations of surface features 84 and sorting holes 86. In this example, surface features 84 have a fixed thickness T=0.014 inches. The screen openings 86 have a fixed length L=0.076 inches and a variable width W. As can be expected, for a fixed number of screen openings 86, the proportion of open area decreases with the width W of each screen opening 86. In this example, the percentage of open area ranges from a minimum of 6.2% open area, for the smallest width, W=0.0017 inches, to a maximum of 23.3% open area, for the largest width, W=0.0071 inches.

table 2

mesh W (inches) W (inches) 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

In table 3 provides additional illustrative configurations of surface elements 84 and sorting holes 86. Table. 3 shows the effect of reducing the length L of the sorting holes 86 and reducing the width T of the surface elements 84 so that the screen element 1860 can contain more screen elements. In this example, the surface features 84 have a fixed thickness of T-0.007 inches. The sorting holes 86 have a fixed length L=0.046 inch and a variable width W. The resulting percentage of open area ranges from a minimum of 10.1% open area, for the smallest width W=0.0017 inch, to a maximum of 27.3% open area for the largest width W=0.0071 inches. Thus, the maximum percentage of open area increases from 23.3 to 27.3% by decreasing T from 0.014 inch to 0.007 inch, and by decreasing L

- 17044418 from 0.076 inches to 0.046 inches, as can be seen when comparing the results of table. 3 with the results of the table. 2. As mentioned above, the increase in the maximum open area fraction occurs because as the size of the sorting holes 86 and surface features is reduced, more sorting holes can be contained on the screen element 1860.

_________________________Table 3____________________

mesh W (inches) W (inches) L(inch) % open area 80 0.0071 0.007 0.046 27.3 100 0.0059 0.007 0.046 25.2 120 0.0049 0.007 0.046 23.1 140 0.0041 0.007 0.046 20.5 170 0.0035 0.007 0.046 18.5 200 0.0029 0.007 0.046 16.5 230 0.0025 0.007 0.046 14.9 270 0.0021 0.007 0.046 12.8 325 0.0017 0.007 0.046 10.1

In table 4 shows additional illustrative configurations of surface elements 84 and sorting holes 86. Tab. Figure 4 shows that the trend can continue. In this example, the surface features 84 have a fixed thickness T=0.005 inches. The sorting holes 86 have a fixed length L=0.032 inches and a variable width W. The resulting percentage of open area ranges from a minimum of 12.1% open area, for the smallest width W=0.0017 inches, to a maximum of 31.4% open area for the largest width W=0.0071 inches. Thus, by decreasing T from 0.007 inch to 0.005 inch, and by decreasing L from 0.046 inch to 0.032 inch, the maximum proportion of open area increases from 27.3 to 31.4%, as can be seen when comparing the results of Table. 4 with the results of the table. 3.

Table 4

mesh W (inches) W (inches) 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 fastening mechanisms in the frame blocks (either in the middle frame blocks 2357 or in the end frame blocks 2355), which can provide or otherwise facilitate the assembly of the sorting unit 2300, which has a certain bend. In one such embodiment, the fastening mechanisms may include latches and latch holes such that the assembled sorting unit 2300 is curved rather than substantially flat, as shown in side views 2350, 2570 and 2390 of the curved sorting unit 2300 shown in FIG. 23B.

In fig. 24 and in fig. 25 illustrates an alternative embodiment of a cartridge assembly 2400 for use in a sorting basket according to the disclosure. The cartridge assembly 2400 includes a removable housing with an upper housing portion 2410 and a separate lower housing portion 2411. The upper housing portion 2410 and the lower housing portion 2411 each include attachment mechanisms 2440 that are releasably engaged with openings 2445 located on the upper housing portion 2410 and the lower housing portion 2411. In use, a screen assembly having screen units 2430 may be mounted to the top or bottom of the housing 2410, 2411, and then the opposite portion of the housing may be mounted around the screen assembly with screen units 2430. The mounting mechanisms 2440 engage holes 2445, securely securing the screen assembly to the screen units. 2430 blocks inside the housing.

The removable housing with an upper housing portion 2410 and a lower housing portion 2411 contains substantially the same features as the housing 1810 discussed herein, including a frame mounting section, a frame section retaining section, and ridges. As shown in the perspective view of the lower housing portion 2411 shown in FIG. 25, frame mounting section 2452 includes internal side walls, and mounting ridges 2420a and 2420b provide or otherwise facilitate installation (at

Claims (31)

example, snapping, clamping, or otherwise engaging) a sorting cartridge assembly 2410 onto a grid frame according to this disclosure, such as a grid frame 1510. Retaining section Frame 2454 may receive and/or support a sorting unit formed by screen units in a manner substantially similar to the method for frame holding section 1854 of housing 1800 discussed in more detail herein. The upper housing portion 2410 and the lower housing portion 2411 may each be formed from a single injection molded part formed integrally by injection molding a polyurethane, thermoset polymer, or other type of polymer. Due to the relative simplicity of separate upper housing portion 2410 and lower housing portion 2411 compared to a single housing (such as housing 1810), the upper housing portion 2410 and lower housing portion 2411 can be more easily created using an injection molding method. Exemplary embodiments of the injection molding process are discussed in more detail in the disclosures of US Patent Application No. 13/800826, US Patent No. 9409209, US Patent No. 9884344, US Patent Application No. 15/851009, US Patent Application No. 15/965195 and the references contained therein, which are incorporated herein by reference in their entirety. Although embodiments of the present disclosure have been described with reference to various embodiments and uses, it will be understood that these embodiments are illustrative and that the scope of the embodiments of the present disclosure is not limited thereto. Many options, modifications, additions and improvements are possible. Therefore, the above description should not be construed as limiting, but only as illustrative of specific embodiments. CLAIM 1. A sorting device comprising a fixed vertical sieve basket forming a plurality of grid holes; a number of sieves attached over the grate holes; wherein each screen has a screening surface, is made of polyurethane or thermoplastic material, and has openings having dimensions ranging from about 35 microns to about 4000 microns, and wherein the dimensions of the openings in each screening surface are configured to separate coal or tar from the coal material slurry in the leach solution (CIL), carbon in the slurry (CIP) or resin in the leach solution (RIL) as the fluid passes from the outside of the screen basket to the inside of the screen basket. 2. The screening device of claim 1, wherein the screens comprise a plurality of screening holes having a length L along a first direction that ranges from about 300 μm to about 4000 μm, and a width W along a second direction that ranges from from about 35 µm to about 4000 µm. 3. The screening device of claim 2, wherein the screens comprise surface elements having a thickness T along the second direction that ranges from about 70 μm to about 400 μm, and wherein the screens have an open screening area of about 5% to about 400 μm. approximately 35% of the total sorting surface area. 4. The sorting device of claim 3, wherein the length L of the sorting holes is approximately 0.1295 inches; the width W of the sorting holes is approximately 0.0182 inches; and the thickness T of the surface element is approximately 0.0283 inches. 5. The sorting device of claim 3, wherein the length L of the sorting holes is approximately 0.1295 inches; the width W of the sorting holes is approximately 0.0214 inches; and the thickness T of the surface element is approximately 0.0252 inches. 6. The sorting device of claim 3, wherein the length L of the sorting holes is approximately 0.1295 inches; the width W of the sorting holes is approximately 0.0262 inches; and the thickness T of the surface element is approximately 0.0241 inches. 7. The screening device of claim 1, wherein the screens comprise a plurality of screening holes, each having a length L that ranges from about 0.7 mm to about 2 mm and a width W that ranges from approximately 35 µm to approximately 150 µm. 8. A screening device according to claim 1, wherein the screens contain openings having a shape that is approximately rectangular, square, round or oval. 9. The sorting device according to claim 1, wherein the sieve basket has a shape suitable for sorting. - 19 044418 10. The screening device according to claim 1, wherein the sieve basket has a cylindrical configuration. 11. A method of filtering a material, the method comprising introducing a slurry stream into the screening apparatus of claim 1 from a tank containing a slurry of material: coal in leach (CIL), carbon in leach (CIP), or resin in leach (RIL), wherein the pulp stream contains resin or activated carbon; both sintering the passage of the slurry fluid from the first side to the second side of the screening surface; filtering the slurry stream through the screening surface from the first side to the second side to thereby remove tar or carbon from the slurry stream so that the tar or carbon is retained on the screening surface. 12. The method according to claim 11, in which the sorting unit contains screen elements that are produced using injection molding. 13. The method of claim 11, wherein the sorting surface is a thermosetting material. 14. The method according to claim 11, in which the sorting surface contains a thermoplastic material. 15. The method according to claim 11, wherein the sorting surface comprises a polyurethane material. 16. The method according to claim 11, in which the sorting surface has a curved shape. 17. The method according to claim 11, in which the sorting unit contains a plurality of individual screen elements. 18. The method of claim 11, wherein allowing the slurry fluid to pass from the first side to the second side of the screening assembly further comprises providing a higher fluid level outside the screening assembly than a fluid level within the screening assembly. 19. A screen basket comprising a substantially vertical grid frame having a plurality of grid openings; a sieve attached over the grid openings, wherein the sieve has a screening surface, is made of polyurethane or thermoplastic material and has holes on the outer surface of the sieve basket, the holes being sized to prevent coal or resin from entering the internal volume of the sieve basket when the basket is immersing carbon in leach (CIL), carbon in pulp (CIP), or resin in leach (RIL) into the material slurry, the openings having sizes ranging from about 35 μm to about 4000 μm. 20. The screen basket device of claim 19, wherein the holes have a smallest size range of from about 0.044 mm to about 4 mm. 21. The screen basket device of claim 19, wherein the openings have a length ranging from about 0.044 mm to about 4 mm and a width ranging from about 0.044 mm to about 60 mm. 22. The screen basket device of claim 19, wherein the holes have a smallest size range of from about 35 microns to about 150 microns. 23. The screen basket device of claim 19, wherein each of the holes has a length ranging from about 0.7 mm to about 2 mm, and a width ranging from about 35 μm to about 150 μm. 24. The sieve basket device according to claim 19, wherein the sieve contains a plurality of individual sieve elements. 25. The screen basket apparatus of claim 19, wherein each of the individual screen elements comprises a molded polyurethane body having screen openings and non-perforated side edge portions, each side edge portion comprising a molded structural member configured to be mechanically connected to the cross member or longitudinal element of the lattice frame, for attaching by means of this separate screen element to the lattice frame. 26. The screen basket device of claim 19, wherein each screen element is a thermoplastic injection molded unitary piece. 27. The sieve basket device according to claim 19, in which the sorting surface has a curved shape. 28. The sieve basket device according to claim 19, wherein the sieve covers a plurality of holes of the lattice frame. 29. The sieve basket device according to claim 19, in which the lattice frame has a cylindrical configuration. 30. The sieve basket device according to claim 19, wherein the sieve is configured to be installed and subsequently removed from the screen frame. 31. The sieve basket device according to claim 30, in which the sieve is a component of the sorting unit -