Haver & Boecker Niagara says it recently custom-engineered the largest vibrating grizzly screen in the world. Manufactured with SSAB Hardox® steel perforated plates and grizzly bars for an unnamed large Brazilian iron ore operation, the Niagara XL-Class vibrating grizzly screen boasts a capacity of 8,000 t/h and a cut size of 200 mm. IM understands the unit is set to be commissioned in Q4 2024.

As the largest exciter-driven machine in the industry, the company says the XL-Class provides the operation with high-capacity screening while maximising uptime and production. Combined with the grizzly technology, the XL-Class has the ability to remove oversize rocks, relieving pressure on the primary crusher.

At 120 tons, the machine’s size required a modular approach, so Haver & Boecker Niagara engineered the XL-Class vibrating grizzly screen as two bodies. The 1.3 m top particle size that the screen had to be able to handle did not allow for the normal placement of exciters, resulting in an adjustment of the design to place three exciters beneath each body rather than the standard overhead location.

“We recognise that no two operations are the same, which is why Haver & Boecker Niagara takes the time to understand each of our customers and their needs for every new quarry or mine location,” said Denilson Moreno, Sales Manager at Haver & Boecker Niagara. “We have worked with this customer for many years, but as they began production at what is the largest iron ore operation in the world, we realised to truly maximise output, it would require a durable and extremely efficient primary screen. That’s what led us to engineer and manufacture this XL-Class, which is now the largest vibrating grizzly screen on the market.”

Haver & Boecker Niagara says it listened to the operation’s challenges and employed their signature NIAflow plant simulation software to address them. The software analysed the proposed plans, processes, goals and material for plant optimisation, providing information to the customer and Haver & Boecker Niagara to design and custom engineer the one-deck vibrating grizzly screen.

To maximise uptime, the customer opted to equip the XL-Class vibrating grizzly screen with Haver & Boecker Niagara’s signature Pulse condition monitoring (Pulse CM) system. The advanced technology provides the producer with 24/7 access to the health of its vibrating screen. Pulse CM includes up to 20 sensors placed on the bearings and bodies, which continually assess the acceleration of the machine and provide a forecast of the equipment’s dynamic condition in intervals of 48 hours, five days and four weeks.

Additionally, the sensors capture real-time information on the monitored equipment and send e-mail alerts to the producer at the first sign of system anomalies. The collected data provides insights into preventive maintenance opportunities, the ability to catch possible issues before they cause unplanned downtime and the peace of mind that the machine is running at peak efficiency.

“Our goal is not only to provide our customers with top-tier equipment but to act as a true consultant and partner to them,” said Clayton Carvalho, Managing Director of Haver & Boecker Niagara’s Brazil operation. “With more than 150 years of experience in the mining and aggregates industry, we are proud of the equipment and technology that we can offer as well as the knowledge and expert service we bring to our customers.”