EA045182B1 - METHOD AND DEVICES FOR SCREENING - Google Patents

Description

Cross reference to related applications

This application claims priority to U.S. Patent Application No. 62/515964, filed June 6, 2017, currently pending, and U.S. Patent Application No. 62/615302, filed Jan. 9, 2018, currently pending. under consideration, the contents of each of which are incorporated herein by reference and the priority of each is hereby asserted.

Brief description of drawings

Various aspects and features of the present invention are described herein with reference to the drawings. Like numerical positions refer to like, but not necessarily the same or identical elements throughout the description.

Fig. 1 shows a side view of a sieve basket in accordance with an example embodiment of the present invention.

Fig. 2 shows a top view of a sieve basket in accordance with an example embodiment of the present invention.

Fig. 3 shows a top view of a sieve basket according to an example embodiment of the present invention.

Fig. 4 shows a top view of a polyurethane screen for use with a basket body, in accordance with an example embodiment of the present invention.

Fig. 5 shows a bottom view of the polyurethane screen of FIG. 4.

Fig. 6 shows a side view of a polyurethane screen for use with a basket body, in accordance with an example embodiment of the present invention.

Fig. 7 is a partial plan view showing the attachment of screen elements to a basket frame, in accordance with an example embodiment of the present invention.

Fig. 8 shows a portion of the polyurethane screen shown in FIG. 4.

Fig. 8A shows an enlarged view of a portion of the polyurethane screen shown in FIG. 8.

Fig. 9 shows a partial side cross-sectional view of a polyurethane screen in accordance with an example embodiment of the present invention.

Fig. 9A shows an enlarged view of a portion of the partial cross-sectional view shown in FIG. 9.

Fig. 10 shows an enlarged partial cross-sectional view substantially along line 1010 of FIG. 9 showing the cross-sectional configuration of the modified shape of the first elements with reinforcing elements, in accordance with an example embodiment of the present invention.

Fig. 11 shows an enlarged partial cross-sectional view similar to that of FIG. 10, however showing the first elements without reinforcing elements, in accordance with an example embodiment of the present invention.

Fig. 12 shows an exploded isometric view of a portion of a polyurethane screen in accordance with an example embodiment of the present invention having reinforcing elements combined with the first and second elements.

Fig. 13 shows an exploded view of a sieve basket application in accordance with an example embodiment of the present invention, in an embodiment of the sieve separator apparatus.

Fig. 14 shows a cross-sectional side view of an example embodiment of using a sieve basket, in accordance with an example embodiment of the present invention, in an embodiment of a sieve separator apparatus.

Fig. 15 is a perspective view of an example of a basket body in accordance with an example embodiment of the present invention.

Fig. 16A shows a perspective view of an example of a screen basket that includes a plurality of screening cartridge assemblies attached to a basket body in accordance with an example embodiment of the present invention.

Fig. 16B shows a partial perspective view of the screen basket shown in FIG. 16A showing a plurality of filter cartridge collections in accordance with an example embodiment of the present invention.

Fig. 16C shows a partial perspective view of the interior of the sieve basket shown in FIG. 16A showing a plurality of filter cartridge collections in accordance with an example embodiment of the present invention.

Fig. 17 shows a partial cross-sectional view of an example of screening cartridge assemblies mounted on a lattice frame in accordance with an example embodiment of the present invention.

Fig. 18A shows an overview of an example of a collection screening cartridge in accordance with an example embodiment of the present invention.

Fig. 18B shows cross-sectional and side views of an example screening cartridge assembly

- 1 045182 zha shown in Fig. 18A. Approximate dimensions, in inches, are shown in the views. The present invention is not limited to such dimensions, and other dimensions may be contemplated.

Fig. 19A is a perspective view of an example of a screening cartridge assembly body in accordance with an example embodiment of the present invention.

Fig. 19B shows cross-sectional and side views of the example housing shown in FIG. 19A. Approximate dimensions, in inches, are shown in the views.

The present invention is not limited to such dimensions, and other dimensions may be contemplated.

Fig. 19C illustrates an example of multiple bodies attached to a lattice frame of a basket body, in accordance with an example embodiment of the present invention.

Fig. 20A shows an example of a prefabricated screen element in accordance with an example embodiment of the present invention.

Fig. 20B illustrates cross-sectional and side views of an example of the prefabricated screen element shown in FIG. 20A. Approximate dimensions, in inches, are shown in the views. The present invention is not limited to such dimensions, and other dimensions may be contemplated.

Fig. 21A shows an overview of an example of a screen assembly frame assembly in accordance with an example embodiment of the present invention.

Fig. 21B shows top and side views of the example frame assembly shown in FIG. 21A.

Fig. 22A shows an example of a screen element of a prefabricated screen, in accordance with an example embodiment of the present invention.

Fig. 22B shows top and side views of the example screen element shown in FIG. 22A.

Fig. 23A shows another example of a prefabricated screen element in accordance with an example embodiment of the present invention.

Fig. 23B shows side views of an example of the precast screen element shown in FIG. 23A.

Fig. 24 shows an example of a sieve element cartridge according to an example embodiment of the present invention.

Fig. 25 shows an example of the lower part of the sieve element cartridge body shown in FIG. 25.

Description of Preferred Embodiments of the Invention

The present invention relates to filtration devices and methods and in particular to the use of improved sieve baskets used in methods and systems for sorption of metals from metal-containing ores. Embodiments of the present invention can be implemented using carbon in pulp (CIP), carbon in caustic (CIL) and resin in caustic (RIL) systems, among others. CIL and CIP systems are, for example, two countercurrent methods for adsorbing leached gold from a slurry stream onto activated carbon. In such CIL and CIP processes, several adsorption tanks are placed in series. The pulp flows continuously from the first reservoir of this sequence to the last reservoir. At the same time, coal is pumped in countercurrent from the last reservoir in a given sequence to the first reservoir. The CIL and CIP processes differ in the extent to which gold is leached prior to carbon adsorption. For example, in a CIL operation, coal is added to leach tanks, and the leach reaction and adsorption 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 process 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 invention are primarily contemplated in relation to gold or coal, embodiments of the present invention can equally be applied to processes for extracting silver, iron, nickel and other metals from their respective ores. The recovery of any metal from the mined ore is within the scope of the present invention.

A description of existing metal screen baskets and methods for their use in the above-described coal-in-pulp (CIP) processes can be found in US Pat. No. 5,238,117. The process described in US Pat. No. 5,238,117 has generally become known in the art as interstage screening processes. vertically moving NKM, and the sieve baskets used therewith have become commonly known in the art as NKM sieve baskets. Typically, these NKM sieve baskets include a metal support frame equipped with a wide wedge sieve located around the perimeter of its side wall. Wedge wire screens are used to filter materials from metal-rich pulp. The sieve basket is attached to the NKM screening device and the lower portion of the NKM screening device, including the attached NKM sieve basket, is immersed in a tank containing coal in the material slurry. The paddle impellers on the NKM screener cause the slurry to pass through the tank and then through the wedge wire screen and into the interior of the NKM screen. However, the wedge wire screen has a very small open screening area, resulting in insufficient screening. Small open screening area

- 2 045182 vaniya also leads to clogging. The clogging, in turn, causes increased volumes of pulp to flow through the unclogged areas of the wedge wire screen, which increases the wear rate of the screen. In addition, the individual wires that form the wedge wire screens are prone to deteriorate or break over time due to forces applied during screening processes such as movement of the internal and external push blades.

In exemplary embodiments of the present invention, a device with an improved sieve basket for screening material is provided. The device includes a support frame having a substantially closed lower portion and an open upper portion, and a substantially cylindrical portion supporting a side wall extending between the lower and upper portions of the support frame.

The support frame may be metal, for example stainless steel. The polyurethane screen side wall extends around and is supported by the side wall supporting part. The polyurethane sieve side wall contains a polyurethane sieve with a high open area. In certain embodiments, the polyurethane screen sidewall substantially encloses the sidewall supporting portion between the closed bottom portion and the open top portion, thereby providing a maximized screening area. The polyurethane screen side wall may be attached to the outer periphery of the side wall supporting portion.

The polyurethane screen sidewall may be formed from a plurality of individual polyurethane screen elements. These individual polyurethane screen elements may be aligned adjacent to one another to provide an overall continuous screening area across the side wall of the screen. In one example, the plurality of individual polyurethane screen elements may include 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 certain embodiments, the substantially closed bottom portion may be provided with a centralized opening that allows the drive shaft of the NKM device to be received.

The high open area polyurethane screen element, in certain embodiments, comprises a flexible molded polyurethane body; sieve holes in a given body; a group of first, substantially parallel, flexible elements defining opposite first sides of the screen openings; a group of second substantially parallel flexible members defining second opposing sides of the screen openings, whereby the second members are substantially perpendicular to the second members; a group of third, essentially parallel, elements having several first elements between them; a group of fourth, substantially parallel elements having several second elements between them; lateral edge portions on substantially opposite sides of the body, between which third elements therein extend; and a first end portion and a second end portion substantially parallel at opposite ends of the body, between which fourth members therein extend, whereby the end portions are substantially perpendicular to the lateral edge portions. The screen openings in the flexible molded polyurethane body of the polyurethane screen element may have a distance of from about 0.044 mm to about 4,000 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 formed within at least one of the first and second elements and at least one of the third 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 (0.1524 mm) to about 0.015 inches (0.381 mm). The reinforcing elements integrally formed with the second elements may have a substantially uniform thickness ranging from about 0.015 inches (0.381 mm) to about 0.040 inches (1.016 mm). The reinforcing elements can be implemented, for example, by means of rods, which can be formed integrally with the elements. Reinforcing elements can also be implemented, for example, by aramid fibers, which are at least one of woven and woven materials, 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 for use in connecting 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 by means of ribs arranged substantially vertically with respect to the side wall supporting portion. Each of the plurality of ribs may extend substantially from the top to the bottom of the polyurethane screen element.

In other embodiments of the present invention, a housing may be provided

- 3 045182 zine, which includes a tubular or substantially cylindrical lattice frame with a plurality of holes. The plurality of openings in the lattice frame may be arranged in a square lattice, and each (or, in some embodiments, at least some) of the plurality of openings may be square in shape. In an example embodiment, the plurality of holes may include 264 square holes. A subset of the plurality of holes may be defined by longitudinal members and transverse members. A second subset of the plurality of openings may be defined by the longitudinal members and transverse segments of the first annular lattice frame section, and likewise, a third subset of the plurality of openings may be defined by the longitudinal members and transverse segments of the second annular lattice frame section.

The basket body may feature flanges on the top and bottom of the body. The flange on the top and the openings may allow or otherwise facilitate the installation of a plate or other type of cover on the flange. In addition or in other embodiments, the flange and openings may allow or otherwise facilitate installation of the basket body into a screen separator device (eg, an NKM interstage vertical motion screening device).

The basket body may be used in a separation process to separate a particular particulate solid from a slurry or other type of fluid source. To this end, in one embodiment, collection sieving cartridges may be mounted on the body of the basket, wherein collection sieving cartridges may enable or otherwise facilitate the separation of a particular particulate solid from the suspension. Each of the screening 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 around the longitudinal axis of the lattice frame, a group of lattice elements that support the first of the screening cartridge assemblies may share a lattice element with another group of lattice elements that support the second of the screening cartridge assemblies.

In some embodiments, each of a plurality of screen collection cartridges mounted or attached to a screen frame includes a screening assembly and a housing (or other type of container) configured to receive and support the screen collection. In some embodiments, the housing may be implemented as a single injection molded assembly that is formed integrally by injection molding of polyurethane, thermoset resin, or other types of resin. Examples of embodiments of an injection molded assembly and the method of forming the injection molded assembly are discussed in more detail in the specifications of US Patent Application No. 13/800826, US Patent No. 9409209, US Patent No. 9884344, US Patent Application No. 15/851009 , U.S. Patent Application No. 15/965,195 and the cross-references incorporated therein, which are hereby incorporated by reference herein in their entirety.

The collection screen has, in some embodiments, three separate screen units. The housing includes a first opening configured to receive and/or install a collecting screen within the housing, and a second opening that exposes the screening surface of the collecting screen to an outer region of the screen frame. The housing also includes projections that extend from a first edge of the housing, proximate the first opening, to an opposite second edge of the housing. The projections and corresponding portions of the housing form corresponding recesses that allow or otherwise facilitate mounting (eg, engaging or attaching) the housing to the lattice frame.

The screen frame of the screen basket may be completely or substantially completely covered by collecting screening cartridges when operating in the separation process. Accordingly, in an example embodiment, 264 screening cartridge assemblies may be mounted on corresponding 264 square holes in the lattice frame.

In addition, the housing may include a connecting frame section and a support frame section. The support frame section may receive and/or support a screen assembly formed by the screen units. The connecting frame section may include a group of projections that define corresponding recesses that in turn allow or otherwise facilitate attachment (eg, by attaching, engaging, or otherwise engaging) the screening cartridge assembly to the lattice frame.

The sieve cartridges in accordance with the present invention may be of any suitable shape for attachment to the lattice frame of the basket body. For example, and without limitation, sieve cartridges may be square or rectangular or oval or any other shape. Although exemplary embodiments may provide screen cartridges that are shaped to substantially conform to the openings of the screen frame (ie, a square screen cartridge on a screen frame with square screen openings), different shapes of screen cartridges may be attached to differently shaped screen openings. Likewise, lattice

- 4 045182 The frame of the basket body can have any shape suitable for screening.

Screen elements and screen cartridges in accordance with the embodiments discussed herein are resistant to wear, abrasion, bending and chemicals more than metal, and accordingly are suitable for operation for a longer time than wedge wire frames, in CIL processes. The screen elements discussed herein also make it possible to form screen openings that are significantly smaller than those in conventional wedge-shaped wire frames, which in turn improves screening efficiency. The use of screen elements as described herein provides significantly larger screening areas and significantly reduces clogging compared to conventional wedge-shaped wire screen baskets. When used, screen elements and screen cartridges as described herein also allow for a substantially constant distance between the outer push blades of the screening device and the collection screen cartridge, thereby reducing clogging and increasing the life of the screen elements.

With reference now to the embodiment shown in FIG. 1-5, the screen basket 1 of the present invention includes a basket frame structure 510 that has a high-open area polyurethane screen 600 attached thereto.

As indicated in FIG. 1, the basket frame 510 generally has a cylindrical configuration, although other shapes may be employed. The basket frame 510 may preferably 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. The embodiment shown in FIG. 3 includes four primary support members 531 spaced along the periphery of the frame 510, together with a plurality of secondary support members 542 located between the primary support members 531. Together, the primary and secondary support members 531, 542 connect the upper and lower ends 511, 515 frame 510 in a split arrangement. The horizontal support members 550 may be provided by a plurality of ring-shaped or curved sections that are butted together to form a plurality of rings at a specified distance along the basket frame 510.

As shown in FIG. 3, each of the vertical support members 531 may include an internal spacer portion 532. The internal spacer portion 532 may, in turn, include holes 534 therein. The horizontal support members 550 extend through the openings 534, thereby supporting the horizontal support members 550 in a separated arrangement one above the other.

As shown in the top view of FIG. 2, the upper end 511 of the frame 510 is provided with an opening to enable use for receiving and processing materials within the screen basket 1. The lower end 515 of the frame 510 is provided with a substantially solid or closed bottom portion 516 for holding materials in the screen basket 1 during processing. The substantially closed lower portion 516 may be provided with a centralized opening 517 for use in production equipment shaft operating locations, as discussed in more detail below.

Embodiments of the present invention may include a high-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 portion 516, and a polyurethane screen sidewall 601.

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

Fig. 4-6 show features of an exemplary embodiment of a screen element 10 configured for use in forming the side wall of a polyurethane screen 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 shows 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, which are filed by the same general assignee as the present invention and are incorporated by reference herein: Patent US No. 8584866; US Patent No. 9010539; US Patent No. 9375756; US Patent No. 9403192; publication of US patent application No. 2015/0197827 A1; and publication of US Patent Application No. 2016/0303611 A1.

As shown in FIG. 4-7, an embodiment of the present invention may include

- 5 045182 screen element 10 with a body 12 formed of polyurethane having non-perforated side edge portions 14, 16. The side edge portions 14, 16 may each have an integrated side extension 29 for use in sealing adjacent screen elements 10 in relation to one another and for securing the screen elements 10 to the basket frame 510, as shown in FIG. 7. Each portion of the side edges 14, 16 may include a molded structural element for use in reinforcing the side projection 29. The side edge portions 14, 16 may also be formed without molded structural elements or may include other structural elements. The side extensions 29 may be in a suitable shape for attachment to the frame of the basket 510. In an exemplary embodiment, the side extensions 29 may include a molded member, such as a metal member, that is curved to a desired shape, such as a U-shaped member, an L- a shaped member, a C-shaped member, or the like. The molded member may be attached to the polyurethane body by heat, pressure, mechanically, chemically, molding, and/or any other suitable method or process.

The body 12 of the screen element 10 also includes lower side edge portions 18 and upper side edge portions 20 which, in combination with the side edge portions 14, 16, define the outer boundary of the screen element 10. In certain embodiments, the side extension 29 may extend throughout the length between the upper side edge portion 20 and the lower side edge portion 18.

Body 12 further includes an outer surface 22 and an inner surface 24. FIG. 4 depicts the outer surface 22 of the body 12 when the screen element 10 is attached to the basket frame 510, as shown, for example, in FIG. 1, and fig. 5 depicts the inner surface 24 of the body 12 when the screen element is attached to the basket frame 510, as shown, for example, in FIG. 1. Body 12 includes first members 101 and second members 102 defining screen openings 26, as shown in detail in FIG. 8 and fig. 8A. The first elements 101 and the second elements 102 may, in some embodiments, be configured to include reinforcing elements 50, as discussed in more detail below. As shown in side view in FIG. 6, screen element 10 may further include vertical ribs 28 on an outer surface 22 of screen element 10. Screen element 10 may, however, not include vertical ribs 28 in certain embodiments of the present invention.

Body 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. The third elements 203, fourth elements 204, and vertical ribs 28 may, however, not include reinforcing elements 50 in certain embodiments of the present invention. The third elements 203 and fourth elements 204 are generally configured to provide support for the screen openings 26 formed by the first and second elements 101, 102.

Fig. 8 shows part of an embodiment of the screen element 10, with FIG. 8A showing an enlarged view of a portion of FIG. 8. As shown in detail in FIG. 8A, the first and second elements 101, 102 form a first integral mesh structure 100 that defines the screen openings 26. The third and fourth elements 203, 204 may form a second integral mesh structure 200, fifth and sixth elements 305 and 306 , accordingly, may in turn form a third integrally formed network structure 300.

Reinforcing elements 50 may be included in desired elements of screen element 10. Reinforcing elements 50 provide stability to screen element 10 by preventing warping or extrusion defects for side edges 14, 16. In a typical embodiment, reinforcing elements 50 may be combined (e.g. by molding in one piece) with the corresponding 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 implemented as rods that are integrally formed with the screen elements. The reinforcing elements 50 may also be implemented as aramid fibers that are at least one of the woven and woven material such that the fibers act as an wicking material to absorb the moldable polyurethane around it, thereby providing a strong bond to the him. The fibers in the form of a woven or woven material may have a linear density of from about 55 denier to about 2840 denier and may preferably have a linear density of about 1500 denier. When aramid fibers are used in embodiments of the present invention, they may be aramid fibers commercially available under the KEVLAR® brand from DuPont. The reinforcing elements 50 may also be at least one of the aramid fibers commercially available under the Teijin trade names TWARON, SULFRON, TEIJINCONEX and TECHNORA. The elasticity of aramid fibers provides a flexible reinforcing system for the molded polyurethane that can be

- 6 045182 rotate to the original molded shape after the necessary twisting and bending that occurs during transport and installation. In certain embodiments, the reinforcing members 50 may be stretched before the polyurethane is molded around them.

Returning back to the example embodiment shown in FIG. 4-5, and a detailed view shown in FIG. 8, the mesh structures 200 and 300 include bidirectionally integrally formed elements that form support meshes within the elements. Due to the properties of the reinforcing elements 50 and the configuration of the bidirectional mesh structure, the elements can be relatively small in size and thereby provide an increased open screening area. The mesh structures provide screen strength and support for the holes 26 during vibration loading and significantly increase the open screening area.

As shown in detail in FIG. 8A, the first elements 101 may extend transversely between the side edge portions 14, 16 such that they are substantially parallel to one another. The second elements 102 may extend transversely between the lower side edge portions 18 and the upper side edge portions 20 such that they are substantially parallel to one another and substantially perpendicular to the first elements 101. In certain embodiments, the second elements 102 may have a thickness greater than the thickness of the first elements 101 to provide additional structural support for the screen openings 26.

As stated above and as shown in exploded isometric view in FIG. 12, 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 support mesh structures. For example, as shown in FIG. 9, which depicts a partial cross-sectional view of the body 12 of the screen element 10, the body 12 has first and second elements 101, 102 together with bidirectional reinforcing elements 50 integrally formed therewith. The reinforcing elements 50 integrally formed with the first elements 101 have a thickness ranging from about 0.006 inches (0.1524 mm) to about 0.015 inches (0.381 mm). The reinforcing elements 50, integrally formed with the second elements 102 (not shown), have a thickness ranging from about 0.015 inches (0.381 mm) to about 0.040 inches (1.016 mm). Such configurations may be advantageous for screening applications requiring screens with larger screen openings.

Embodiments of the present invention may include reinforcing elements 50 in any one of the first, second, third and fourth elements 101, 102, 203, 204, as well as in the ribs 28, and may be included in all or part of the first, second, third and fourth elements 101, 102, 203, 204 and ribs 28.

As shown in FIG. 8 and in more detail in Fig. 8A, the screen holes 26 may be elongated, with a greater length dimension along the sides and between their ends than the width dimensions. The screen holes 26 may be from about 0.044 mm to about 4.0 mm in width, the width being the dimension between the inner surfaces of adjacent first members 101. The screen holes 26 may be from about 0.44 mm to about 60 mm in length, the length being the size between the internal surfaces of adjacent second elements 102. The screen openings 26 may further have various shapes. For example, the screen openings 26 may have a rectangular shape or a square shape or an oval 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 from about 1.2 meters by 1.6 meters or may be any other desired size. It is understood that all dimensions shown herein are provided as an example and without limitation.

With reference briefly to FIG. 10 and fig. 11, the screen openings 26 may be deflected downward between the outer surface 22 and the inner surface 24, with the first elements 101 being substantially in the shape of 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 integrally formed with the reinforcing elements 50, as shown in FIG. 10, or may optionally not include reinforcing elements 50 integrally formed therewith, as shown in FIG. eleven.

As illustrated in detail in FIG. 8A, the third and fourth elements 203, 204 may have a thickness greater than the first and second elements 101, 102. The increased thickness of the third and fourth elements 203, 204 may provide additional structural support for the first and second elements 101, 102. As shown in the example embodiment in FIG. 8 and 8A, the third elements 203 may extend transversely between the lateral edge portions 14, 16 substantially parallel to one another, and may have a plurality of first elements 101 disposed therebetween. The fourth elements 204 may extend transversely between the lower side edge portions 18 and the upper side edge portions 20 such that they are substantially parallel to one another and may have multiple second elements 102 disposed therebetween.

The reinforcing elements 50 may be integrally formed with the third and fourth elements

- 7 045182 elements 203, 204. The third and fourth elements 203, 204 can be configured to have a minimum thickness by including reinforcing elements 50, while maintaining the necessary structural support for the screen openings 26 formed by the first and second elements 101, 102, during the application of vibration screening. The bidirectional support system provided by the third and fourth elements 203, 204, and the additional support of the reinforcing elements 50 integrated therewith included herein, significantly reduces the thickness of the support elements and provides increased open screening area and overall screen efficiency.

Body 12 may further include a plurality of vertical ribs 28. In the embodiment shown in FIG. 4-6, a sequence of nine edges 28 can be provided. The ribs 28 may have a thickness greater than the thickness of the third and fourth members 203, 204 and may have a portion protruding from the inner surface 24 of the body 12. As shown in FIG. 2, ribs 28 may also extend from the outer surface 522 of the body 12 and thereby provide vertical support along the side wall 600 of the outer screen. The greater thickness and positioning of the ribs 28 provides additional structural support for the first and second elements 101, 102.

The ribs 28 may extend transversely between the lower side edge portions 18 and the upper side edge portions 20 such that they are substantially parallel to one another, and may have multiple fourth members 204 disposed therebetween. The ribs 28 may additionally and alternatively be extended transversely between the lateral edge portions 14, 16 such that they are substantially parallel to one another, and may have a plurality of third members 203 disposed therebetween. The ribs 28 may have reinforcing elements 50 integrally formed therewith. Ribs 28 may be provided to provide additional support to the screen openings 26 and may be configured to have a minimum thickness through the inclusion of reinforcing members 50, while providing the necessary structural support to support the screen openings 26 during vibratory screening applications. Like the third and fourth elements 203, 204, the provision of a fin support system 28 significantly reduces the thickness of the support elements and provides increased open screening 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 a relatively high tensile strength with relatively small cross-sectional areas.

Each element of the screen element 10 may include such reinforcing elements 50 and may not include or include one or more reinforcing elements 50, and the reinforcing elements 50 used may be of different sizes and materials. Reinforcing elements 50 may be located in the lower element halves 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 bi-directional support frame support elements, makes it possible for the first elements 101, as well as the second elements 102, to be relatively thin, creating larger screen openings. Embodiments as described herein have relatively high tensile strengths over relatively small cross-sectional areas. The shape of the support elements and the thin first elements 101 results in the screen element 10 and the screen 600 as a whole having a greater percentage of open area, which in turn increases the throughput of the system. The open screening areas in accordance with the embodiments described herein may range from, for example, about 40 percent to about 46 percent of the screen.

In accordance with an embodiment of the present invention, 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 lower side edge portions 18 substantially perpendicular to the side edge portions 14. 16, and upper side edge portions 20 substantially perpendicular to the side edge portions 14, 16 and opposite the lower side edge portions 18. The polyurethane body 12 further includes an outer surface 22 and an inner surface 24. First and second aperture defining members 101, 102 are provided. 26 for screening. The first elements 101 extend between the side edge portions 14, 16, and the second elements 102 extend between the lower and upper side edge portions 18, 20. The body 12 may also include third and fourth elements 203, 204, such that the third and fourth elements 203 , 204 have a thickness greater than the thickness of the first and second elements 101, 102. The third elements 203 operate substantially parallel to one another and extend transversely between the lateral edge portions 14, 16 and have a plurality of first elements 101 disposed therebetween. The fourth elements 204 operate substantially parallel to one another and

- 8 045182 extend transversely between the lower and upper side edge portions 18, 20 and have several second elements 102 located between them. Reinforcing elements 50 may be integrally formed with third and/or fourth elements 203, 204, and further reinforcing elements or rods may be integrally formed with fourth elements 204. Body 12 also includes ribs 28. Ribs 28 may be substantially parallel to one another and extending transversely between the side edge portions 14, 16. The ribs 28 may also be substantially parallel to one another and extending transversely between the lower and upper side edge portions 18, 20. The ribs 28 are thicker than the third and fourth elements 203, 204, and may include reinforcing elements 50 integrally formed therewith. The body 12 may further have fifth and sixth elements 305, 306. The fifth elements 305 operate substantially parallel to one another and extend transversely between the lateral edge portions 14, 16 and have a plurality of third elements 203 disposed therebetween. The sixth elements 306 operate substantially parallel to one another and extend transversely between the lower and upper side edge portions 18, 20 and have a plurality of fourth elements 204 disposed therebetween. The reinforcing elements 50 may be integrally formed with the fifth and/or sixth elements 305, 306, and additional reinforcing elements or rods may be integrally formed with the sixth elements 306.

Screen elements in accordance with this embodiment may have open screening areas greater than 40 percent and mesh sizes ranging from about 0.375 mesh to about 400 mesh. As an example, tested screens having the above configurations included a 43 mesh screen, a 140 mesh screen, and a 210 mesh screen. Each of these screens had open screening areas ranging from about 40 percent to about 46 percent. Such large screening areas for such relatively small dimensions are achieved by a relatively strong and thin lattice frame structure created by the third, fourth, fifth and sixth members 203, 204, 305, 306 and by reinforcing members integrally formed therewith.

In the above embodiments and examples, the size of each lattice unit formed by the intersection of the third and fourth elements 203, 204 is approximately 1 inch by 1 inch. In general, the screen units can be larger for screens with larger screen openings, and the screen units can be smaller for screens with smaller screen openings. This principle may be generally applicable to each example embodiment discussed herein. The grid units 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 side wall 601 on the basket frame has significant advantages over conventional wedge wire screens. Polyurethane screen elements 10, as described herein, resist wear, abrasion, distortion and chemicals more than metal and accordingly tend to last longer in CIL processes than wedge wire frames. Polyurethane also offers the ability to form significantly smaller screen openings than those of conventional wedge wire frames, which in turn improves screening efficiency. The use of polyurethane screen elements 10, as described herein, provides significantly larger screening areas and significantly reduces clogging compared to conventional wedge-shaped wire screen baskets.

In operation, the screen basket 1 described herein can be used in conjunction with known CIP and CIL devices and processes, such as those described in US Pat. No. 5,238,117. For example, as shown in FIG. 13-14, the sieve basket 1 is connected below the spiral part of the interstage screening device with movement in the vertical direction NKM. The drive shaft of the NKM device runs from the top to the bottom of the sieve basket 1 and through a centralized hole in the closed bottom of the sieve basket 1. The gearbox and motor are located above the helix to drive the drive shaft. The outlet interface is located above the polyurethane screen and the spiral interface to receive the discharged slurry flow.

Together with the sieve basket 1 attached to the NKM device, the lower part of the NKM device, including the sieve basket 1, is inserted into and suspended on top of a large adsorption tank containing the slurry of pulp to be processed. The slurry level in the tank is higher than the liquid level in Sieve Basket 1. This arrangement causes the slurry to flow naturally through the sieve of Sieve Basket 1 to equalize the liquid levels in the slurry tank and Sieve Basket 1. The blades on the outside of the NKM assembly rotate inside the tank around outer periphery of the screen side wall of the sieve basket 1. The outer side of the blades also takes part in preventing particles from clogging the outer side of the polyurethane screen, such as coal and pulp. Pulsing and sweeping reduces the possibility of coal and material clogging the screen openings

- 9 045182 of similar size. Impeller blades on the inside of the screen, such as on a drive shaft, serve to keep the particles in suspension and cause the slurry to move upward toward the helix and discharge port.

During the process, the pulp flows upward through the interior of sieve basket 1. The coal remains on the sieve. The existing pulp is located above the polyurethane screen and the spiral interface through the interface at the drain hole.

In these processes, it can be seen that the continuous rotation of the inner and outer blades near 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. The polyurethane screens and screen basket arrangement described herein are designed to withstand significant wear and tear and are substantially superior to existing wire screen baskets in CIP and CIL processes.

Although the screen basket 1 has been described for use in a CIP or CIL process, the relatively small openings and relatively large screening area of the polyurethane screen elements 10 described herein make it possible to use the screen basket 1 for other purposes, such as filtration and desalination.

Fig. 15 illustrates an overview of an example basket body 1500 in accordance with a further embodiment of the present invention. The basket body 1500 includes a lattice frame 1510 that is tubular (or has substantially cylindrical symmetry) with respect to a longitudinal axis and has a plurality of openings 1513. As such, the 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 example embodiment, the height is about 80 inches (about 203.2 cm), and the diameter is about 50 inches (about 127 cm). It should be noted that the present invention is not limited to such exemplary height and/or diameter values, and other dimensions of the lattice frame 1510 may be contemplated. In addition, the lattice frame 1510 is not limited to tubular or cylindrical symmetry, but may be formed in any configuration suitable for screening, and especially for screening coal, as discussed herein. Screen frame 1510 may also be formed from any material that provides sufficient structure for the screening process and sufficient support for screening cartridges that will be attached to screen frame 1510. For example, screen frame 1510 may be formed from metal or a metal alloy such as stainless steel. , or may be a thermoplastic material suitable for supporting screening cartridges. In embodiments featuring a thermoplastic lattice frame 1510, the lattice frame 1510 may comprise a single injection molded assembly. In other embodiments, the lattice frame 1510 may be formed from individual elements joined together to form the lattice frame 1510.

In certain embodiments, the lattice frame 1510 can be formed into a desired shape by bending the perforated sheet itself, about a longitudinal axis, and connecting opposite ends of the perforated sheet. The joined opposite ends may form a longitudinal joint 1515. In some embodiments, the perforated sheet may be formed from a metal or metal alloy (eg, stainless steel), and the opposite ends may be joined by welding. In other embodiments, the perforated sheets may be formed from rigid plastic and the opposite ends 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 openings 1513 may have shapes other than a square shape, such as a rectangular shape, an oval shape, a circular shape, and the like. Additionally, the plurality of openings 1513 do not need to have a consistent shape throughout the lattice frame 1510. For example, some embodiments may provide alternative rectangular openings of varying sizes to define the overall lattice frame 1510. In an example embodiment, the plurality of openings 1513 may include 264 square openings. A subset of a plurality of holes may be defined 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 a plurality of openings may be defined by longitudinal members 1511 and transverse segments of a first annular section 1512a of the lattice frame 1510. Likewise, a third subset of a plurality of openings may be defined by longitudinal members 1511 and transverse segments of a second annular section 1512b of the lattice frame 1510. The second subset and the third subgroup of holes can be classified as external holes.

The first annular section 1512a and the second annular section 1512b may combine or otherwise constitute respective opposing end portions of the lattice frame 1510, along

- 10 045182 longitudinal axis. A flange 1520 may be attached or otherwise attached to the end of the first annular section 1512a. The flange 1520 may include a plurality of first openings 1525. The flange 1520 and the first openings 1525 may allow or otherwise facilitate the installation of a plate or other type of covering on the flange 1520. In addition or in other embodiments, the flange 1520 and the first openings 1525 may allow or otherwise facilitate installation of the basket body 1500 into a screen separator device (eg, an NKM interstage vertical motion screening device, as shown in FIG. 13 and FIG. 14). In addition, the second flange 1530 may be attached or otherwise attached to the second annular section 1512b. The second flange 1530 may include a plurality of second openings 1535. The flange 1530 and the second openings 1535 may allow or otherwise facilitate installation of the basket body 1500 into a screen separator apparatus (e.g., an NKM interstage vertical motion screening apparatus, as shown in FIG. 13 and Fig. 14) and/or connecting the external cleaning assembly of the device with a sieve separator (not shown).

As illustrated in FIG. 15, the basket body 1500 may also include an opening proximate the second end of the lattice frame 1510, adjacent the second flange 1530. The tubular member 1540 may be mounted proximate the opening. The opening and tubular member 1540 may define an outlet that may allow or otherwise facilitate the release of slurry from the interior of the basket body 1500 when it needs to be drained upon removal.

Like other screen baskets of the present invention, the basket body 1500 in combination with screening elements can be used in a separation process to separate a particular particulate solid from a slurry or other type of fluid source. To this end, in one embodiment, screening cartridge collections may be mounted on the body of the basket 1500, wherein screening cartridge collections may enable or otherwise facilitate the separation of a particular particulate solid from the suspension. Specifically, by way of illustration, FIG. 16A is an overview of an example screen basket 1600 that includes a plurality of screening cartridge collections 1610 in accordance with one or more embodiments of the present invention. The plurality of sieving collection cartridges includes a first sieving collection cartridge 1610a, a second sieving collection cartridge 1610b, and a third sieving collection cartridge 1610c. Each of the screening cartridge assemblies 1610a, 1610b, 1610c may be mounted or otherwise attached to a corresponding group of screen elements that define, at least in part, a respective opening of the grid frame 1510. The screening cartridge assemblies 1610 may be removable such that the screening cartridge assemblies may be mounted on the basket body 1500 and then 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 around the longitudinal axis of the lattice frame 1510, a group of lattice elements that support the first of screening cartridge assemblies 1610a and 1610b may share a grid element with another group of grid elements that support the second of screening cartridge assemblies 1610a and 1610b. More specifically, in one example, the first screening cartridge assembly 1610a may be clamped or otherwise connected to the first longitudinal member and the second longitudinal member of the lattice frame 1510. Additionally, the second screening assembly 1610b may be clamped or otherwise connected to the second longitudinal member. and to the third longitudinal element.

In some embodiments, each of a plurality of screen collection cartridges mounted or attached to the screen frame 1510 includes a screen assembly and a housing (or other type of container) configured to receive and support a screen collection. In some embodiments, the housing may be implemented as a single injection molded assembly that is formed integrally by injection molding of polyurethane, thermoset polymer, or other types of polymers. Examples of embodiments of an injection molded assembly and the method of forming the injection molded assembly are discussed in more detail in the specifications of US Patent Application No. 13/800826, US Patent No. 9409209, US Patent No. 9884344, US Patent Application No. 15/851009 , U.S. Patent Application No. 15/965,195 and the cross-references incorporated therein, which are hereby incorporated by reference herein in their entirety. The housing and the screening assembly supported therein may be of any shape and structure suitable for mounting on a lattice frame. In some embodiments, the housing and screening assembly may be substantially rectangular. In other embodiments, the housing and screening assembly may be square in shape, or may be oval in shape, or may be triangular in shape, etc.

As illustrated in FIG. 16B, screening cartridge assembly 1610a includes a housing 1630a and a screen assembly having three screen units 1640a. It should be noted that the present invention

- 11 045182 is not limited to three screen units, and, in some embodiments, fewer or additional number of screen units may be used. For a given screen assembly size, a larger number of screen assemblies results in a larger housing 1630a, which consequently results in a larger screening cartridge assembly. Oversized prefabricated screening cartridges can be used in grid frames having larger grid openings.

Housing 1630a includes a first opening configured to receive and/or install a collection screen within housing 1630a. The housing 1630a also includes a second opening that exposes the screening surface of the screen assembly to the outer region of the screen frame 1510. The screening surface may be implemented as a substantially seamless and flat surface or may include, for example, such a surface including a plurality of screening openings. , having, for example, essentially the same size and/or essentially the same shape. The plurality of screening holes may have a rectangular shape, a square shape, a circular shape, a combination thereof, or the like. Moreover, as illustrated in FIG. 16C, housing 1630 also includes projections 1650a that extend from a first edge of housing 1630a, proximate the first opening, to an opposing second edge of housing 1630a. The projections 1650a and corresponding portions of the housing 1630a define corresponding recesses that allow or otherwise facilitate installation (e.g., engagement or attachment) of the housing 1630a to the lattice frame 1510. The housing 1630a may be permanently mounted to the lattice frame 1510 through the use of the projections 1650a and corresponding portions. housing 1630a, or may be removably mounted on the lattice frame 1510 so that housing 1630a can be removed as needed for maintenance or repair.

Likewise, the screening cartridge collection 1610b includes a housing 1630b and a screen collection having three screen units 1640b. As stated, the present invention is not limited to three screen units, and, in some embodiments, fewer or additional number of screen units may be used. Housing 1630b also includes a first opening configured to receive and/or install a collection screen within housing 1630b. The housing 1630b also includes a second opening that exposes the screening surface of the screen assembly to the outer region of the screen frame 1510. The screening surface may be implemented as a substantially seamless and flat surface or may include, for example, such a surface including a plurality of screening openings. , having, for example, essentially the same size and/or essentially the same shape. Moreover, as illustrated in FIG. 16C, housing 1630b also includes projections 1650b that extend from a first edge of housing 1630b, proximal to the first openings, to an opposing second edge of housing 1630b. The projections 1650b and corresponding portions of the housing 1630b may define corresponding recesses that allow or otherwise facilitate installation (eg, engagement or attachment) of the housing 1630b on the screen frame 1510. With respect to the collection screen contained in the housing 1630b, as further illustrated in FIG. 16C and FIG. 17, each of the screen assemblies 1640b includes a frame assembly having one or more screen elements attached to a surface of the frame assembly, and the screen assemblies 1640b may be mechanically coupled or otherwise secured to form a screen assembly. To this end, each of the screen assemblies 1640, such as those illustrated at reference to 1640b, may include one or more fastening means that may enable or otherwise facilitate fastening of the first one of the screen assemblies (e.g., screen assembly 1640a) to the second one. from sieve units (for example, 1640b). Regardless of the connection mechanism of the screen units 1640b, respective screen elements of the screen units 1640 may form a screening surface that may be exposed to slurry in the outer region of the screen frame 1510.

In some embodiments, each (or, in other embodiments, at least one) of the screen elements may be included in a single assembly manufactured in one piece by injection molding of a thermoplastic material. An example of thermoplastic materials and methods for creating an example of thermoplastic materials used as screen elements in the present invention are discussed in detail in the specifications 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. 15/965,195 and the cross-references incorporated therein, which are incorporated by reference herein in their entirety.

The screening cartridge assembly 1610c, like the screening cartridge assembly 1610a, 1610b, also includes a housing 1630c and a screen assembly having three screen units (not shown in FIG. 16B). As stated, the present invention is not limited to three screen units, and, in some embodiments, fewer or additional number of screen units may be used. Housing 1630c also includes a first opening configured to receive and/or install a collection screen within housing 1630c. Housing 1630c also includes a second opening that allows or otherwise facilitates the screening surface of the screen assembly to be open to the outer region of the screen frame 1510. The screening surface may be implemented as a substantially seamless and flat surface or may include, for example , that

- 12 045182 shaped surface including a plurality of screening holes having, for example, substantially the same size and/or substantially the same shape. Moreover, as illustrated in FIG. 16C, housing 1630c also includes projections 1650c that extend from a first edge of housing 1630c, proximate the first opening, to an opposing second edge of housing 1630c. The projections 1650c and corresponding portions of the housing 1630c define corresponding recesses that allow or otherwise facilitate mounting (eg, engaging or attaching) the housing 1630c to the lattice frame 1510. FIG. 17 illustrates the mechanical connection of the screening cartridge assembly 1610a and screening cartridge assembly 1610b to the transverse lattice elements of the lattice frame 1510. As indicated, the projections 1650a allow or otherwise facilitate installation of the screening cartridge assembly 1610a on the lattice frame 1510. Likewise, the projections 1650b enable or otherwise facilitate installation of the screening cartridge assembly 1610a on the lattice frame 1510. otherwise facilitate installation of screening cartridge assembly 1610b on grid frame 1510.

The screening collection cartridge 1610a and the screening collection cartridge 1610b include respective collection screens. The collection screen contained in the collection cartridge 1610a includes three screen units 1640a in accordance with the embodiments described herein. Another collection screen contained in the collection cartridge 1610b includes three screen units in accordance with the embodiments described herein. As stated, the present invention is not limited to prefabricated screens having three screen units, and, in some embodiments, fewer or additional number of screen units may be used.

Prefabricated sieves having different numbers of sieve units can also be realized.

In connection with the collection screen contained in housing 1630c, as further illustrated in FIG. 16C, each of the screen assemblies that make up the screen assembly includes a frame assembly having a screen element attached to a surface of the frame assembly. The screen assemblies may be mechanically connected or otherwise secured to form a screen assembly. To this end, in an embodiment, each of the screen assemblies may include one or more fastening means that may enable or otherwise facilitate fastening of the first one of the screen assemblies to the second one of the screen assemblies. Regardless of the connection mechanism of the screen units, corresponding screen elements of the screen units 1640 may form a screening surface that may be exposed in the outer region of the screen frame 1510.

It should be noted that while three screening cartridge assemblies are illustrated in FIG. 16A-16C and FIG. 17, the screen frame 1510 of the screen basket 1600 may be completely or substantially completely covered to function during the separation process. Accordingly, in an example embodiment, 264 screening cartridge assemblies may be mounted on corresponding 264 square holes 1513 in the lattice frame embodiment 1510.

Fig. 18A illustrates an overview of an example screening cartridge assembly 1800, in accordance with one or more embodiments of the present invention. An exemplary screening cartridge assembly 1800 includes a housing 1810 and a screen assembly having three screen units 1830. As noted, the present invention is not limited to three screen units, and, in some embodiments, fewer or additional screen units may be used. The housing 1810 is generally arcuate in shape and includes a first opening configured to receive and/or install a collection screen within the housing 1810. The housing also includes a first projection 1820a and a second projection 1820b. Each of the protrusion 1820a and protrusion 1820b extends from a space near the first, upper edge of the housing 1810 to a space near the opposite second, lower edge of the housing 1810. In use, the arcuate shape of the housing 1810 allows for a substantially constant distance between the outer push blades of the screening device and the collection screening cartridge, thereby reducing clogging and increasing the service life of the screen elements.

Like other screening cartridge assemblies of the present invention, as illustrated in cross-sectional top view 1850 of screening cartridge assemblies 1800 shown in FIG. 18B, each of the screen assemblies 1830 may include two end frame assemblies 1855 and a single middle frame assembly 1857, each of the two end frame assemblies 1855 and the single middle frame assembly 1857 having a screen element 1860 attached to a corresponding surface of the frame assemblies.

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

- 13 045182

As illustrated in cross-sectional views 1850 and 1870 shown in FIGS. 18B, housing 1810 may include a connecting frame section 1852 and a support frame section 1854. The connecting frame section 1852 and the support frame section 1854 are also illustrated in the overview view of the housing 1810 shown in FIG. 19A. Support frame section 1854 may receive and/or support a screen assembly formed by screen units 1830. To this end, in some embodiments, support frame 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 internal side walls are not visible in the overall 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 support frame section 1854. Side wall 1920, in connection with side walls 1930 and 1980, may define a first opening, and opposite side wall 1960, in connection with side walls 1930 and 1980, may define a second opening. The second hole may have a cross-sectional area larger than the cross-sectional area of the first hole in order to reduce undesirable reduction in screening area. The smaller cross-section may provide greater mechanical stability for screen collections located within the housing 1810. The first opening and the second opening may allow particulate solid matter to flow from the exterior to the interior of the screening cartridge collection including the housing 1810. particles may be screened or otherwise separated by means of such a collection screen. Specifically, the particulate solid may be separated from an external slurry external to the screen basket assembly having a screening cartridge assembly including the screen assembly and may flow into the interior region of the screen basket assembly as intended or required for use for screening (for example, in the CIL process, the CIP process, ore processing, water desalination, etc.).

As further illustrated in cross-sectional views 1870 and 1970 in FIG. 18B and FIG. 19B, accordingly, the support frame section 1284 may include a protrusion 1872 proximal to the opening configured to receive a collection screen, and a protrusion 1874 proximate the base of the housing 1810.

Additionally, with further reference to FIG. 19A, the connecting frame section 1852 includes inner side walls, including a side wall 1946 and a side wall 1948, as well as other side walls respectively opposite thereto. One of such opposing side walls may be seen in side view 1990 in FIG. 19V. Namely, the side wall 1992 is opposite the side wall 1946. The connecting frame section 1852 also includes a projection 1820a and a projection 1820b. In one embodiment, protrusion 1820a and protrusion 1820b and corresponding portions of connection frame section 1852 define corresponding recesses 1856. Such recesses, as indicated, may allow or otherwise facilitate installation (e.g., attaching, engaging, or otherwise engaging) a screening assembly cartridge 1800 on a trellis frame of the present invention, such as the trellis frame 1510 described earlier herein. By way of illustration, FIG. 19C depicts four housings 1810 each mounted adjacent to each other on a grid frame 1510. Corresponding four prefabricated screens may be inserted or otherwise mounted within the four housings 1810 to form four screening cartridges and assemble a screen basket for multiple separation processes, such as CIL process, CIP process, water filtration and desalination, etc.

Fig. 20A illustrates an example of a screen assembly 2000 in accordance with one or more embodiments of the present invention. The exemplary collection screen 2000 may be located or otherwise mounted within housing 1810 or any other housing described herein to form a screening cartridge collection in accordance with the present invention. In accordance with other screen assemblies described herein, the screen assembly 2000 includes three frame assemblies, which may include two end frame assemblies 1855 and a single middle frame assembly 1857, each of the end frame assemblies 1855 and the middle frame assembly 1857 includes screen elements 1860 , attached to them. The present invention is not limited to three frame assemblies 1855, 1857 and/or a certain number of screen elements 1860 per frame assembly 1855, 1857. In some embodiments, two screen elements 1860 may be attached to each of three frame assemblies 1855, 1857. In some embodiments implementation, fewer or additional numbers of frame assemblies 1855, 1857 and/or screen elements 1860 may be used. Each (or, in some embodiments, at least one) of the frame assemblies 1855, 1857 may be included in a single unit manufactured in one piece by injection molding of a polymer. The frame assemblies 1855, 1857 may be mechanically connected or otherwise secured to form a screen assembly 2000. To this end, in an embodiment, each of the frame assemblies 1855, 1857 may include one or more fasteners that may enable or otherwise facilitate the fastening of the first one of the frame units 1855, 1857 with the second one of the frame units 1855, 1857. Regardless

- 14 045182 Simultaneously with the mechanism that is used or that otherwise relates to the connection of frame assemblies, the connected frame assemblies 1855, 1857 form a first segmented edge element and an opposing second segmented edge element (not visible in Fig. 20A). The connected frame assemblies 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 assemblies 1855, 1857, respectively.

The screen elements 1860 attached to each of the frame assemblies 1855, 1857 may form a screening surface of the screen assembly 2000 and a screening cartridge assembly that includes the screen assembly 2000. The screening surface may be substantially seamless, as illustrated in cross-sectional views of the assembly 2050 and 2070 sieves 2000 in Fig. 20V. In some embodiments, as illustrated in side view 2090 of screen assembly 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 screening holes. Such sections may be separated by support members (represented by dotted lines in plan view 2090). The present invention is not limited to screen elements having four sections, and, in some embodiments, fewer or additional sections having screening holes may be used.

Fig. 21A illustrates an overview of a middle frame assembly 1857 in accordance with one or more embodiments of the present invention. The middle frame assembly 1857 is elongated and includes longitudinal side members 2138 located opposite and substantially parallel to one another. The middle frame assembly 1857 also includes transverse side members 2136 located opposite and substantially parallel to one another. Each transverse side member 2136 is substantially perpendicular to the longitudinal side members 2138. As indicated, the middle frame assembly 1857 may include fastening mechanisms that allow or otherwise facilitate mechanical connection or otherwise fastening of the middle frame assembly 1857 and another frame assembly (end frame node 1855 or middle frame node 1857). Namely, in some embodiments, fastening mechanisms may be assembled or otherwise formed on respective portions of the longitudinal side members 2138, with the transverse side members 2136 not associated with the fastening mechanisms. As illustrated in FIG. 21A, in at least one such embodiment, fastening mechanisms may be included in or may include clamps 2142 and clamp holes 2140. A middle frame assembly 1857 and another frame assembly (e.g., an end frame assembly 1855) also having clamps 2142 and clamp holes holes 2140 may be mechanically coupled or otherwise secured along their respective longitudinal side members 2138. To this end, in one embodiment, the clamp 2142 of the middle frame assembly 1857 may be passed into the clamp hole 2140 of the other frame assembly until the elongated elements of the clamp 2142 will extend beyond the clamp opening 2140 and the longitudinal side member of the other frame assembly. When the clip 2142 is slid into the clip opening 2140, the extension members of the clip 2142 can be pressed together until the attachment portion of each extension member is located outside the longitudinal side member of the other frame assembly, providing attachment portions for engagement with the interior of the longitudinal side member of the other frame assembly. When the attachment portions are engaged into the clamp opening 2140, the longitudinal side members of two independent frame assemblies can be adjacent and secured together (eg, mechanically connected). The frame assemblies can be separated by applying force to the continuing members of the clamps such that the continuing elements move forward with each other, allowing the attachment portions to pass the opening 2140 of the clamp. Although the fasteners described herein and shown in the drawings are clamps and clamp holes, the present invention is not limited in this regard, and alternative fasteners and alternative clamp and/or hole shapes may be used, including other mechanical arrangements, adhesives, and so on.

The middle frame assembly 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 of the transverse support members 2148 is substantially parallel to the transverse side members 2136 and 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 assembly 1857. In addition, the longitudinal support members 2146 and transverse support members 2148 may provide mechanical stability to the screen element that is attached to the middle frame assembly 1857.

The middle frame assembly 1857 may also include second transverse support members 2145 substantially perpendicular to the longitudinal side members 2138. As illustrated in FIG. 21A and side view 2170 of FIG. 21B, the second lateral support members 2145 may be distributed

- 15 045182 along the screen openings in the middle frame assembly 1857. The second transverse support members 2145 may provide additional mechanical stability to the screen element that is attached to the middle frame assembly 1857.

To enable or otherwise facilitate attachment of one or more screen elements to the middle frame assembly 1857, attachment elements 2144 and several adhesive means are included in the middle frame assembly 1857. As illustrated in side view 2190 of the middle frame assembly 1857 shown in FIG. . 21B, the first coupling means includes a plurality of coupling rods 2172 mounted (eg, formed) on the surfaces of the longitudinal side members 2138. As shown in a top view 2150 of the middle frame assembly 1857 in FIG. 21B, the second coupling means includes a plurality of coupling rods 2152 mounted (eg, formed) on the surfaces of the transverse side members 2136 and the transverse support members 2148. As shown in a side view 2170 of the middle frame assembly 1857 of FIG. 21B, the third connection means includes a plurality of connection bars 2176. In some embodiments, the connection bars 2176 may have a height that is less than the height of the connection bars 2172 and also less than the height of the connection bars 2152.

In some embodiments, the attached members 2144 may enable or otherwise facilitate alignment of the laser welded screen element with respect to the middle frame assembly 1857 or other type of frame assembly described herein. Attached members 2144 and/or various connecting rods may be fused during laser welding.

The end frame assemblies 1855 may have a structure similar to that of the middle frame assembly 1857. The fastening mechanisms in the end frame assembly 1855 may be included in a single longitudinal side member of the frame assembly 1855.

In some embodiments, the screen element may be implemented as or may be included in the screen element 1860, as illustrated 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 one another, 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 one another, and each of the second side portions 2222 are substantially perpendicular to the first side portions 2220. Each of the side portions 2220 is configured to be positioned and attached to transverse side members (e.g., members 2136) of the frame assembly 1855, 1857 (e.g., middle frame assembly 1857) in accordance with embodiments of the present invention. As such, each of the side portions 2220 may include cavities configured to receive or otherwise secure connecting rods to the surface of the transverse side members. Likewise, the side portions 2222 are configured to accommodate longitudinal side members of the frame assembly 1855, 1857 (eg, frame assembly 1857) in accordance with this invention. Accordingly, each of the side portions 2222 includes cavities configured to receive or otherwise secure connecting rods to 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 collinear and substantially perpendicular to support elements 2238. Support elements 2238 are also substantially collinear. The screen element 1860 also includes support elements 2240 that extend from the first one of the side portions 2222 to the second one of the side portions 2222. Each of the support elements 2230, 2238, and 2240 is configured to be located or attached to the corresponding support elements of the frame assembly 1855 , 1857, such as the middle frame assembly 1857. Accordingly, each of the support elements 2230, 2238 and 2240 includes cavities configured to receive or otherwise secure connecting rods to a corresponding surface of the frame assembly support elements.

Screen element 1860 further includes attached holes 2224. One of the connected holes 2224 is located substantially in the center of screen element 1860. Other attached holes 2224 are located at corresponding angles with respect to the seamless periphery of screen element 1860. Regardless of location in screen element 1860, each one ( or, in some embodiments, at least one) embodiment of the opening 2224 is configured to allow or otherwise facilitate passage of the elongated attachment member 2144 (e.g., FIG. 21A) through the attached opening 2224. In one or more such embodiments, the attached openings 2224 may include a tapered bore that can be filled when a portion of the elongated attachment member 2144 above the screening surface of the screen element 1860 is fused, connecting the screen element 1860 to the middle frame assembly 1857 or another type of frame assembly described herein. IN

- 16 045182 In other embodiments, the attached holes 2224 can be configured without a tapered bore, allowing droplets to form on the screening surface 2013 of the screen element 1860 when a portion of the elongated attached element 2144, above which the screening surface is fused, connects the screen element 1860 to the middle frame assembly. 1857 or other type of frame assembly described in this document. The screen element 1860 may cover half of a portion of the middle frame assembly 1857 (or other type of frame assembly described herein), and each of the four sections included in the screen element 1860 may respectively cover the four screen holes of the middle frame assembly 1857.

Screening surface 2213 has a plurality of screening holes. Each one (or, in some embodiments, at least some) of the plurality of screening holes may be elongated and may have a specific length and a specific width having appropriate dimensions based on the screening application (e.g., CIL process, CIP process, ore processing, water desalting, or the like), which utilizes a screen element 1860. In some embodiments, the plurality of screening holes may be of the same substantially uniform length, ranging from about 300 microns to 4000 microns. µm. In addition, the plurality of screening holes may have the same substantially uniform width, ranging from about 35 µm to 4000 µm. By way of illustration, in some embodiments, the width may be approximately 43 μm, 74 μm, 90 μm, 104 μm, 125 μm, 150 μm, 180 μm, 500 μm, 700 μm, or 1000 μm (1 mm). In an example embodiment, the plurality of screening holes may be of substantially the same length, having a value of approximately 500 μm. As illustrated in FIG. 22A and FIG. 22B (showing top and side views 2250, 2270, and 2290 of screen element 1860), a plurality of holes may be arranged in sections, with screening holes in a section located in the grid. Each of the sections is defined, at least in part, by support members 2230, 2238, and 2240 of screen element 1860. In one embodiment, screening openings that are adjacent to the periphery of screen element 1860 may be defined by longitudinal bars parallel to the first lateral ones. portions of the screen element 1860, cross bars perpendicular to the longitudinal bars, and segments of the edges of the side portions of the screen element 1860. In addition, screen holes that are located in the interior of the section may be defined by the longitudinal bars and cross bars. The longitudinal bars define the major side of the elongated holes, and the cross bars define the minor side of the elongated holes.

As illustrated in FIG. 23A and 23B, some embodiments may include fastening mechanisms in frame assemblies (middle frame assemblies 2357 or end frame assemblies 2355) that may allow or otherwise facilitate the arrangement of screen assembly 2300 that has a certain curvature. In one such embodiment, the fastening mechanisms may include clamps and clamping holes such that the assembled screen assembly 2300 is curved rather than substantially flat, as shown in side views 2350, 2570, and 2390 of the curved screen assembly 2300 shown. in fig. 23V.

Fig. 24 and fig. 25 illustrate an alternative embodiment of a cartridge assembly 2400 for use in a screening basket of the present invention. 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 fastening mechanisms 2440 that can be releasably inserted into openings 2445 that feature the upper housing portion 2410 and the lower housing portion 2411. In use, a screen assembly having screen assemblies 2430 may be installed in the upper or lower portions of the housing 2410, 2411, and the opposite portion of the housing may then be mounted around the screen assembly with screening assemblies 2430. Fastening mechanisms 2440 engage with holes 2445, securing the assembly sieve with 2430 units for screening reliably inside the housing.

The removable housing with an upper housing portion 2410 and a lower housing portion 2411 includes substantially the same elements as the housing 1810 discussed herein, including a connecting frame section, a support frame section, and projections. As shown in the overall view of the lower housing portion 2411 illustrated in FIG. 25, a connecting frame section 2452 includes inner side walls, and attached projections 2420a and 2420b enable or otherwise facilitate mounting (e.g., attaching, engaging, or otherwise engaging) screening cartridge assemblies 2410 onto the lattice frame of the present invention, such as a lattice frame 1510. The support frame section 2454 may receive and/or support a screen assembly formed by the screen units in a manner that is similar to that discussed in more detail herein for the support frame section 1854 of the housing 1800.

The upper housing portion 2410 and the lower housing portion 2411 may each be formed as a single unit, manufactured in one piece by injection molding of polyurethane, thermoset resin, or other types of resin. Due to the comparative simplicity of the separate upper housing portion 2410 and lower housing portion 2411, as related to

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Claims (58)

a single housing (such as housing 1810), the upper housing portion 2410 and the lower housing portion 2411 can be more easily created through an injection molding process. Examples of embodiments of the injection molding process are discussed in more detail in the specifications 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 cross-references included therein, which are incorporated by reference herein in their entirety. While embodiments of the present invention have been described with reference to various embodiments and applications, it is to be understood that these embodiments are illustrative and that the scope of these embodiments of the present invention is not limited thereto. Many variations, modifications, additions and improvements are possible. The above description should therefore not be construed as limiting, but merely as illustrative examples of particular embodiments. CLAIM 1. A screen basket comprising a substantially cylindrical lattice frame (1510) having a plurality of openings (1513), the lattice frame comprising a plurality of transverse members (1512) and a plurality of longitudinal members (1511) that define a plurality of openings (1513); and a first screening assembly comprising at least one first screen element (1860) defining a first screening surface (2213) comprising at least one of polyurethane and thermoplastic material and located on the outer side of the screen frame (1510), the first screen element (1860) includes holes having sizes ranging from about 35 μm to about 4000 μm and having an open screening area from about 40% to about 46% of the screening surface area (2213); and a second screening assembly comprising at least one second screen element (1860) defining a second screening surface (2213) comprising at least one of polyurethane and thermoplastic material, and located on the outer side of the screen frame (1510), the second screen element element (1860) includes holes having sizes ranging from about 35 μm to about 4000 μm and having an open screening area from about 40% to about 46% of the area of the screening surface (2213); wherein the dimensions of the holes and the open screening area of the first and second sieve elements (1860) of the first and second screening units provide the possibility of separating, using a sieve basket, particles of coal or tar from a suspension of material in the form of coal in alkali (CIL), coal in pulp (CIP) or resin in alkali (RIL) when the slurry material passes from the outside of the sieve basket into the sieve basket, at least in part due to the fact that the first fluid level outside the sieve basket exceeds the second fluid level inside the sieve basket, creating a static difference pressure between the fluid outside relative to the fluid inside the screen basket, and so that the coal or resin particles are retained on the outer surfaces of the first and second screen elements. 2. The screen basket according to claim 1, further comprising a first screening cartridge assembly (1800) including a first housing (1810) and a first screening assembly (1830) secured within the first housing (1810); a second screening cartridge assembly (1800) including a second housing (1810) and a second screening assembly (1830) secured within the second housing (1810); wherein the first screening cartridge assembly (1800) is coupled to at least one of (a) a first cross member (1512) and a second cross member (1512) of the plurality of cross members and (b) a first longitudinal member and a second longitudinal member of the plurality of longitudinal members (1512) such that the first screening cartridge assembly (1800) covers the first hole (1513) of the plurality of holes (1513) of the lattice frame (1510), the second screening cartridge assembly (1800) is attached to at least one of the third transverse element (1512) and a fourth transverse element (1512) of a plurality of transverse elements (1512) and (b) a third longitudinal element (1511) and a fourth longitudinal element (1511) of a plurality of longitudinal elements (1511), so that the second screening cartridge assembly ( 1800) covers a second opening (1513) of the plurality of openings of the screen frame (1510), and wherein the screen basket further includes a third screening cartridge assembly (1800) that is coupled to at least one of the fifth cross member (1512) and the sixth cross member (1512) of a plurality of transverse members (1512) or a fifth longitudinal member (1511) and a sixth longitudinal member (1511) of a plurality of longitudinal members (1511) such that a third screening cartridge assembly (1800) covers a third opening (1513) of a plurality of openings lattice frame (1510). 3. The sieve basket according to claim 2, in which the first housing (1810) includes a support section (1854) - 18 045182 frame, configured to receive the first screening unit. 4. The screen basket of claim 3, wherein the first body (1810) further includes a connecting frame section (1852) seamlessly integrated with the support frame section (1854), the connecting frame section (1852) includes a first elongated projection (1820a) and a second elongated protrusion (1820b) opposite and substantially parallel to the first elongated protrusion (1820a), wherein a first recess (1856) is formed between the first protrusion (1820a) and the first portion of the connecting frame section (1852), and wherein the second recess (1856) formed between the second projection (1820b) and the second part of the connecting frame section (1852). 5. The screen basket according to claim 4, wherein the first recess (1856) is configured to secure at least one of the first transverse element (1512) or the first longitudinal element (1511), and wherein the second recess (1856) is configured to securing at least one of the second transverse element (1512) and the second longitudinal element (1511). 6. The screen basket of claim 1, wherein the first screening assembly and the second screening assembly each include a frame (1857) having structural members that define screen openings; while the screen elements (1860) are attached to the frame (1857). 7. The screen basket of claim 6, wherein the first screening unit frame (1857) and the second screening unit frame (1857) are mechanically connected to form one of a flat base structure or an arcuate base structure. 8. The screen basket according to claim 7, wherein the first screening unit frame (1857) and the second screening unit frame (1857) each include a first longitudinal side member (2138) and a second longitudinal side member (2138), wherein at least one of the first longitudinal side element and the second longitudinal side element includes fastening means (2140, 2142) configured to be mechanically connected to the other frame. 9. The screen basket of claim 8, wherein the fastening means includes at least one of clamps (2142) and clamp holes (2140). 10. The screen basket of claim 6, wherein the first screening unit frame (1857) and the second screening unit frame (1857) are each elongated and include a first longitudinal side member (2138) and a second longitudinal side member (2138) opposite and substantially parallel to the first longitudinal side member; and a first transverse side member (2136) and a second transverse side member (2136) opposite and substantially parallel to the first transverse side member; wherein the first transverse side member (2136) is substantially perpendicular to each of the first longitudinal side member (2138) and the second longitudinal side member (2138); and wherein the second transverse side member (2136) is substantially perpendicular to each of the first longitudinal side member (2138) and the second longitudinal side member (2138). 11. The screen basket according to claim 1, wherein the screen frame (1510) contains metal and has a certain height and a certain diameter. 12. The sieve basket according to claim 11, in which the metal is stainless steel. 13. The sieve basket according to claim 11, wherein the specified height is in the range of about 60 cm to about 370 cm, and the specified diameter is in the range of from about 25 cm to about 250 cm. 14. The sieve basket according to claim 13, wherein the determined height is about 203.2 cm and the determined diameter is about 127.0 cm. 15. The screen basket of claim 6, wherein the screen elements (1860) are each a single unit manufactured integrally by injection molding of a thermoplastic material, wherein the screening surfaces (2213) formed by the screen elements (1860 ) are a substantially flat screening surface (2213), and the screen elements (1860) have a plurality of elongated screening holes. 16. The screen basket of claim 15, wherein each of the plurality of elongated screening holes has the same substantially equal length and the same substantially equal width, wherein the substantially equal length has a value in the range from about 300 μm to about 4000 μm, and the substantially uniform width ranges from about 35 μm to about 4000 μm. 17. The screen basket of claim 16, wherein the substantially uniform width is approximately one of 43 μm, 74 μm, 90 μm, 125 μm, 150 μm, 180 μm, 500 μm, or 700 μm. 18. The screen basket of claim 2, wherein the first housing is a removable housing including a first upper housing portion (2410) and a first lower housing portion (2411) separable from the first upper housing portion (2410), and wherein the second housing is a removable housing including a second upper housing portion (2410) and a second lower housing portion (2411) separable from the second upper - 19 045182 parts (2410) of the housing. 19. The screen basket of claim 18, wherein at least one of the first upper housing portion (2410) and the first lower housing portion (2411) includes fastening mechanisms (2440) removably engaged with holes (2445) on the other of the first upper housing portion (2410) and the first lower housing portion (2411), and wherein at least one of the second upper housing portion (2410) and the second lower housing portion (2411) includes fastening mechanisms (2440) configured to removably engaging with openings (2445) on the other of a second upper housing portion (2410) and a second lower housing portion (2411). 20. A screening device configured to screen material, comprising a reservoir containing a suspension of coal in alkali (CIL), coal in pulp (CIP) or resin in alkali (RIL) material; a sieve basket located inside the tank in a fixed vertical configuration; a polyurethane screen (600) attached to a screen basket support frame (510), wherein the polyurethane screen (600) defines a screening surface facing the outside of the screen basket and having an open screening area of about 40% to about 46% of the area of the polyurethane screen, wherein the polyurethane screen (600) includes holes (26) having sizes ranging from about 35 μm to about 4000 μm such that the polyurethane screen (600) allows the screen basket to separate coal or tar particles from the material suspension as the material in the suspension passes from the outside of the sieve basket to the inside of the sieve basket, at least in part due to the fact that the first level of fluid outside the sieve basket exceeds the second level of fluid inside the sieve basket, and so that particles of coal and tar from the suspension are retained on the screening surface. 21. The screening device according to claim 20, wherein the polyurethane screen comprises first elements (101) and second elements (102) arranged such that screen holes (26) are formed between the first and second elements, and wherein the screen holes have a length from about 0.44 mm to about 4 mm between the internal surfaces of the first elements and a length from about 0.44 mm to about 60 mm between the internal surfaces of the second elements. 22. The screening device according to claim 20, wherein the polyurethane screen (600) includes first elements (101) and second elements (102), which include reinforcing elements (50) integrally manufactured therewith by injection molding. 23. The screening apparatus of claim 22, wherein the reinforcing members (50) integrally injection molded with the first members (101) have a thickness ranging from about 0.005 inch to about 0.015 inch, and wherein the reinforcing members (50), integrally injection molded with the second members (102), have a thickness ranging from about 0.015 inch to about 0.040 inch. 24. The screening device according to claim 20, wherein the polyurethane screen (600) further comprises a flexible polyurethane-molded body including screen holes (26) in the body, first substantially parallel flexible elements (101) defining opposite sides screen holes, and second substantially parallel flexible members (102) that are substantially perpendicular to the first elements (101) and define other opposite sides of the screen holes (26); third substantially parallel elements having first elements (203) between them, and fourth essentially parallel elements (204) having second elements (102) between them; side edge portions extending substantially parallel at opposite ends of the body, between which third elements extend, the third elements (203) and fourth elements (204) being configured to support the screen openings (26); end portions extending substantially parallel at opposite ends of the body, between which fourth elements (204) extend; and reinforcing elements (50) integrally formed with at least one of the first and third elements and at least one of the second and fourth elements, the side edge portions being substantially perpendicular to the end portions. 25. A screen basket comprising a substantially cylindrical screen frame (1510) having a plurality of holes (1513); and a screening assembly comprising at least one screen element (1860) forming a screening surface (2213) comprising at least one of polyurethane and thermoplastic material and attached above an opening (1513) of the plurality of holes of the screen frame (1510), the screen the element (1860) has holes with a diameter ranging from about 35 μm to about 4000 μm and has an open screening area from about 40% to about 46% of the area of the screening surface (2213); and wherein the dimensions of the openings in the sieve element (1860) enable the sieve basket to separate coal or tar particles from a suspension of material in the form of coal in caustic (CIL), coal in slurry (CIP) or tar in caustic (RIL) when the material is in suspension passes outside the sieve basket - 20 045182 inside the sieve basket and so that the coal and tar particles are retained on the outer surface of the screening surface. 26. The screen basket of claim 25, wherein the screen frame (1510) includes a plurality of transverse members (1512) and a plurality of longitudinal members (1511) that define a plurality of openings (1513). 27. The screen basket of claim 25, further comprising a second screening assembly comprising at least one screen element (1860) forming a screening surface (2213) and comprising at least one of polyurethane and thermoplastic material. 28. The screen basket of claim 27, wherein the second screening assembly covers a second opening (1513) of the plurality of openings of the screen frame (1510). 29. The screen basket of claim 25, wherein the screen element (1860) comprises a single assembly manufactured in one piece by injection molding of a thermoplastic material. 30. The screen basket of claim 29, wherein the mesh size of the screening surface is from about 0.375 mesh to about 400 mesh. 31. The screen basket of claim 25, wherein the screening assembly includes a frame (1857) and the screen member (1860) is attached to the frame (1857). 32. A screen basket comprising a lattice frame (1510) having a plurality of openings (1513), the lattice frame including a plurality of transverse members (1512) and a plurality of longitudinal members (1511) that define a plurality of openings (1513); a screen attached to the outside of the screen frame defining a synthetic screening surface (2213) and comprising at least one of a polyurethane and a thermoplastic material, the screen including openings and having an open screening area of about 40% to about 46% of the area of the synthetic screening surface, and the open screening area of the screen allows the screen to be used in coal-in-liquor (CIL), coal-in-pulp (CIP), or tar-in-liquor (RIL) systems to filter coal and tar particles from the slurry stream so that the particles coal and resin are retained on the outer surface of the screen. 33. The screen basket of claim 32, wherein the screen includes a thermosetting material. 34. The sieve basket of claim 32, wherein the sieve includes a plurality of sieve holes, each having a length L that ranges from about 0.7 mm to about 2 mm and a width W that ranges from about 35 µm to about 150 µm. 35. The sieve basket according to claim 32, wherein the sieve includes a thermoplastic material. 36. The sieve basket according to claim 32, wherein the sieve includes a polyurethane material. 37. The sieve basket according to claim 32, wherein the sieve is a single unit manufactured by injection molding. 38. The sieve basket according to claim 32, in which the sieve has a corrugated shape. 39. The sieve basket according to claim 32, wherein the sieve covers a plurality of holes (1513) of the screen frame (1510). 40. The screen basket of claim 32, wherein the screen includes a plurality of individual screen elements. 41. The screen basket of claim 40, wherein each of the individual screen elements includes a molded body having screen openings and non-perforated side edge portions, wherein each side edge portion includes a molded structural member that is configured to be mechanically coupled to a transverse member or a longitudinal member. a lattice frame element for thus attaching a separate screen element to the lattice frame. 42. The screen basket according to claim 32, wherein the screen frame (1510) has a cylindrical configuration. 43. A screening device comprising a sieve basket containing a lattice frame (1510) having a plurality of holes (1513); and a screen forming a synthetic screening surface (2213) and containing at least one of a polyurethane and a thermoplastic material, the screen including screen openings having opening sizes ranging from about 35 microns to about 4000 microns, and having an open screening area of about 40 % to about 46% of the total screen area, attached to the outside of the screen frame, the size of the screening holes and the open screening area of the screen allowing the screen to separate coal or tar particles from a suspension of material in the form of coal in alkali (CIL) , coal in pulp (CIP) or tar in alkali (RIL), when the slurry material passes from the outside into the screen basket, at least in part due to the fact that the first level of fluid outside the screen basket exceeds the second level of fluid inside the screen basket, and so that the coal and resin particles are retained on the outer surface of the screen. 44. The screening device of claim 43, wherein the screen includes a thermosetting material. - 21 045182 45. The screening apparatus of claim 43, wherein the screen includes a plurality of screen holes, each having a length L that ranges from about 0.7 mm to about 2 mm, and a width W that ranges from from about 35 µm to about 150 µm. 46. The screening device of claim 43, wherein the screen includes a thermoplastic material. 47. The screening device of claim 43, wherein the screen includes a polyurethane material. 48. The screening device of claim 43, wherein the screen is a single injection molded unit. 49. Screening device according to claim 43, in which the sieve has a corrugated shape. 50. The screening device according to claim 43, wherein the sieve covers a plurality of holes (1513) of the screen frame (1510). 51. The screening device of claim 43, wherein the screen includes a plurality of individual screen elements. 52. The screening apparatus of claim 51, wherein each of the individual screen elements includes a molded body having screen openings and non-perforated side edge portions, each side edge portion including a molded structural member that is mechanically coupled to the cross member or longitudinal element of the lattice frame for attaching, therefore, a separate screen element to the lattice frame. 53. The screening device according to claim 43, wherein the screen frame (1510) has a cylindrical configuration. 54. A sieve basket containing a substantially cylindrical frame (1510); and a screen forming a synthetic screening surface (2213) and containing at least one of a polyurethane and a thermoplastic material, the screen being attached to a frame and having opening sizes ranging from about 35 microns to about 4000 microns, and having an open screening area of about 40 % to about 46% of the total screening surface area, with the size of the holes at the screening holes allowing the sieve to separate coal or tar particles from a suspension of material in the form of coal in alkali (CIL), carbon in pulp (CIP) or tar in alkali (RIL) where the slurry material passes from the outside of the sieve basket to the inside of the sieve basket so that the coal and resin particles are retained on the outer surface of the sieve. 55. The screen basket of claim 54, wherein the cylindrical frame is a screen frame (1510) and the screen includes a plurality of replaceable screening units attached to the screen frame (1510). 56. The screen basket of claim 55, wherein the screen frame (1510) has a plurality of openings and each of the plurality of openings is configured to receive a corresponding one of a plurality of replaceable screening units. 57. A screen basket comprising a substantially cylindrical screen frame (1510) having a plurality of openings (1513), the screen frame including a plurality of first members (1512) and a plurality of second members (1511) that define a plurality of openings, a plurality of independent, replaceable screening units wherein each screening assembly is mounted on at least one of the openings (1513) and each screening assembly includes a screen forming a synthetic screening surface (2213) and formed as a single unit manufactured in one piece by injection molding of a thermoplastic material and having screening holes with hole sizes ranging from about 35 µm to about 4000 µm and with an open screening area of about 40% to about 46% of the total screening surface area; the screening holes being sized to allow the screening basket to separate coal or tar particles from a suspension of material in the form of coal in caustic (CIL), coal in slurry (CIP) or tar in caustic (RIL) as the slurry material passes outside the device in the form of a sieve basket inside the sieve basket, at least in part due to the fact that the first level of fluid outside the sieve basket exceeds the second level of fluid inside the sieve basket. 58. The screen basket of claim 57, wherein at least one of the plurality of openings includes a fastening mechanism configured to attach at least one of the independent, replaceable screening assemblies to at least one of the plurality of openings. -