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Derrick Stack Sizer™

for the Coal Industry

Illinois Mining Institute

 August 2012 Meeting

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Company Profile

• Derrick Corporation is a private company

founded in 1951 by H. William Derrick

• 500,000 ft2 (46,452 m2) manufacturing

facility located at 590 Duke Road in Buffalo,

New York

• Focus on fine screening applications in themining, industrial, chemical and oil & gas

drilling industries

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2011 Plant Expansion

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2011 Plant Expansion

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2011 Plant Expansion

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2011 Plant Expansion

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Buffalo, New York USA

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Niagara Falls, New York USA

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Buffalo, New York USA

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Recent Advances in

Fine Screening Technology

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Key Derrick Corporation Product

Developments for the Coal Industry

• 1977 – Sandwich Screen® woven wire panel

• 1977 – Multifeed screening machine

• 1989 – Polyurethane screen surfaces• 1990 – Hi-G™ Dryer screen (8 Gs) 

• 1993 – Pyramid™ screen surface (3 dimensional) 

• 1997 – Super G™ vibrating motor  

• 2001 – Stack Sizer™ screening machine 

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5 Deck Stack Sizer

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Stack Sizer Screen

• Derrick Corporation’s Newest Wet Sizing

Technology – Combination of Linear

Motion with the use of Derrick High Open Area Polyurethane Screen Panels

• High Efficiency Separations

• High Tonnage Rates

• Minimal Operator Involvement

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Principle of Operation

5-way flowdistributor

Dual vibrating

Motors for

linear motion

OversizeUndersize

Various

feed box

configurations

Easy access

between decks

Undersize

collection manifold

Undersize collection

pans under each

of 5 screen decks

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Fine Polyurethane

Screen Surfaces

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Fine Polyurethane

Screen Surfaces

• Panels currently used in coal sizing

applications: 180, 150, 100 and 75 μm

• Panel Life - 12 to 24 months

• Panels now available for coal sizing

applications: 63, 53 and 45 μm 

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Stack Sizer Applications in the

Coal Industry

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Fine Sizing Coal

at 150 micron (100 mesh)

Removal of High Ash/Sulphur Fractionfrom

Clean Coal Spiral Product

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Typical Clean Coal Spiral Product

Screening Flow Diagram

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Coal Feed onto 100 micron Urethane Panel 

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Action of Stack Sizer Repulp Trough 

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Coal Sizing on 100 micron Urethane Panels 

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Clean Coal Spiral Product Application

Installation Photos

James River Coal Company

Kentucky, USA

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Fine Sizing Coal

at 75 micron (200 mesh)

Removal of -75 micron Fractionfrom

152mm (6”) Hydrocylcone Underflow 

T i l 6” H d l U d fl

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Typical 6” Hydrocyclone Underflow

Screening Flow Diagram

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6” Hydrocyclone Underflow

Application

Installation Photos

Kentucky & Illinois, USA

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Discussions

Classification vs Fine Clean Coal Ash

 – The presence of high ash ultrafine coal and clay

increases the fine clean coal ash. H.M circuit sometimes

needs to be compromised.

 –Removal of high ash ultrafine coal and clay will

decreases the fine clean coal ash . The higher the

classification efficiency, the cleaner the fine clean coal.

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Discussions

Modified Finch Partition Model:

Plitt Partition Model:

Whiten Partition Model:

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Discussions

Simulation Results:

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Discussions

Simulation Results:

40

4550

55

60

65

70

75

80

85

90

60 70 80 90 100

   P  e  r  c  e  n   t  a  g  e   % 

Efficiency %

Comb. Recovery

Ash Rejection

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Paul Brodzik, P.E.Product Applications Engineer

Baojie Zhang, Ph.D.

Product Applications Engineer

590 Duke Road · Buffalo, NY 14225

Ph: 716.683.9010 · Fax: 716.683.4991

E-mail: pbrodzik@derrickcorp.com