Using its fine screening expertise in gold processing, Derrick has simplified a previously arduous maintenance process and transformed a problem that originated at a customer’s gold processing plant into a major success story.
Derrick’s penchant for continual innovation in fine screening technology has led to development of the G-Vault urethane interstage screen to replace the wedge wire interstage screen.
Wedge wire screens have traditionally required rigorous maintenance, which has created worker dissatisfaction.
For example, a Canada-based mining company faced resignations from workers due to the responsibility for daily maintenance of wedge wire screens.
Troubles such as this have plagued the carbon-in-leach (CIL)/carbon-in-pulp (CIP) and resin-in-leach (RIL)/resin-in-pulp (RIP) gold processing methods for many years.
Backed by 70 years of experience in fine screening, Derrick was determined to improve gold processing methods.
Its research led to development of the G-Vault urethane interstage screen, which has changed the way gold is recovered.
“Our G-Vault urethane interstage screen is non-blinding and has up to 20 per cent higher open area to allow more throughput, which eventually leads to increased production,” Derrick new product applications specialist Patrick Stasio tells Australian Mining.
But it is not only the innovative G-Vault that Derrick has delivered to the gold processing industry, it is also a new development process that made the G-Vault screen a reality.
In Derrick’s design process, dimensions and process information from the mining company’s current interstage screen are used by Derrick engineers to design the appropriate G-Vault screen to fit into their processing plant.
By working closely with the mining company, Derrick’s design team ensures that the custom screen meets the customer’s needs.
Using a computer program, the custom retrofit screen is drawn from start to finish to occupy the same footprint as the wedge wire interstage screen it will replace.
The G-Vault retrofit screen is then fabricated and shipped to the mine site as a direct bolt-in replacement for the mine’s current wedge wire screen.
Replacement is made even easier by the customisable design of G-Vault. One G-Vault screen comprises several modular screens and cartridges.
“The Derrick team has designed G-Vaults from as small as two square metres to as large as 24 square metres, depending on the current interstage screen at the mine site. We can design custom solutions for them,” Stasio says.
“The modular screens give the mine site flexibility. When a site needs to replace a section of the G-Vault screen, they only need to replace the one or two affected cartridges instead of replacing the entire wedge wire screen.
“The G-Vault on-site procedures are similar to the current wedge wire procedures they already have on site. We are not rewriting procedures. This familiarity makes for an easy on-site adaptation process for installation.”
Such simple maintenance contradicts the demands of the wedge wire screen, which needs to be fully replaced or power washed when it loses effectiveness.
Stasio says the G-Vault urethane screen saves costs, time and labour. He does, however, concede that the release of G-Vault has been met with skepticism.
He says that problems involving the use of wedge wire interstage screens have lasted for such a long time that many operators don’t believe they would all be resolved with just one product.
“We’ve spoken with mining companies and confirmed that most are having the same problem with wedge wire screens everywhere,” Stasio says.
“So now it’s about re-educating site operators to have a different outlook on gold screening with regards to interstage screens.”
The G-Vault screen has exceeded many user expectations, with the screen now installed in eight countries.
Its urethane material lives up to its rough and tough reputation as a high-tolerance synthetic screen in the gold processing industry.
From increasing gold recovery to reducing operating and maintenance costs, the G-Vault is making its mark on gold processing.
As a world leader in developing state-of-the-art solutions to improve operations and increase recovery, Derrick is committed to the gold processing industry.
Innovative solutions offered by Derrick are reducing waste and raising efficiency to help propel the industry to greater heights and higher profitability.
This story also appears in the April issue of Australian Mining.