Overview
A global solids processor producing activated carbon for a wide range of industrial and consumer applications experienced rapid business growth that placed new demands on its screening operations. The company needed to serve multiple end markets, each with different particle size and quality requirements, while maintaining high throughput and consistent product performance.
As production volumes and application complexity increased, existing screening equipment struggled to deliver the efficiency, yield, and reliability required for continued growth.
Challenges
The activated carbon processing operation faced several key challenges:
- Uneven material distribution across screening surfaces
- Frequent screen blinding and clogging
- Reduced product yield due to inefficient separation
- High maintenance demands associated with traditional vibratory screeners
- Difficulty screening both fine-grade and coarse materials on the same platform
- Limited flexibility to support a wide range of product specifications
These issues led to wasted material, increased downtime, and rising maintenance costs.
Solutions
A high-efficiency gyratory screening solution was implemented to replace conventional vibratory separators and support diverse activated carbon applications.
Key elements of the solution included:
- Gyratory reciprocating motion to evenly stratify and convey material across the screen surface
- Rectangular screening decks designed for improved particle contact and separation
- Segmented screen panels allowing multiple mesh sizes on a single deck
- Screen cleaning systems that reduce blinding and maintain consistent performance
- Side-access doors enabling fast screen inspection, cleaning, and changeovers
- Wear-resistant options for handling coarser, more abrasive carbon materials
The system was validated through material testing to ensure it could meet both fine-particle precision and high-output requirements.
Results
The upgraded screening solution delivered meaningful operational improvements:
- Increased screening efficiency and improved product yield
- Reduced material waste and reprocessing
- Consistent separation across a wide range of particle sizes
- Significantly lower maintenance effort and downtime
- Faster cleaning and screen changeovers
- Improved overall productivity and operational flexibility
The processor was able to support continued growth while improving reliability, efficiency, and product quality across multiple activated carbon applications.
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