<p>Observations on roller screens in real working conditions revealed that the deck angle and the rollers’ speed are two key factors that significantly affect device efficiency. In this research, a new design called the “Differential Speed Regime” is proposed and evaluated experimentally to determine its effectiveness in enhancing device efficiency. To conduct the experiments, an experimental rig was built and installed in an iron pelletizing factory to replicate real conditions. The rig was tested with the production output of a real pelletizing disk. Based on the obtained experimental results, the effects of each introduced variable individually, as well as their cross-effects, were explored and discussed. The results showed that the proposed approach successfully improved screen efficiency. In this regard, the maximum attainable efficiency of the conventional roller screen is around 72%, whereas the proposed design achieves more than 82%. However, it was revealed that to attain maximum efficiency, the influential parameters need to be set at optimal values. For instance, to achieve the best efficiency, for deck angle of <InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="42461_2025_1194_Article_IEq1.gif" Format="GIF" Height="14" Rendition="HTML" Resolution="72" Type="Linedraw" Width="17" /> </InlineMediaObject> <EquationSource Format="TEX">$6^\circ$</EquationSource> <EquationSource Format="MATHML"><math> <msup> <mn>6</mn> <mo>∘</mo> </msup> </math></EquationSource> </InlineEquation>, the roller’s speed should be around 160 rpm while, for angles of <InlineEquation ID="IEq2"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="42461_2025_1194_Article_IEq2.gif" Format="GIF" Height="14" Rendition="HTML" Resolution="72" Type="Linedraw" Width="25" /> </InlineMediaObject> <EquationSource Format="TEX">$12^\circ$</EquationSource> <EquationSource Format="MATHML"><math> <msup> <mn>12</mn> <mo>∘</mo> </msup> </math></EquationSource> </InlineEquation> and <InlineEquation ID="IEq3"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="42461_2025_1194_Article_IEq3.gif" Format="GIF" Height="14" Rendition="HTML" Resolution="72" Type="Linedraw" Width="25" /> </InlineMediaObject> <EquationSource Format="TEX">$18^\circ$</EquationSource> <EquationSource Format="MATHML"><math> <msup> <mn>18</mn> <mo>∘</mo> </msup> </math></EquationSource> </InlineEquation>, it should be around 120 and 80 rpm, respectively.</p>

A New Design of the Roller Screen to Improve the Device Efficiency

期刊论文
发表日期：

2025年5月19日

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Akbar Jafari,
Amir Mohamad Poorhosein,
Javad Paidar

摘要

Observations on roller screens in real working conditions revealed that the deck angle and the rollers’ speed are two key factors that significantly affect device efficiency. In this research, a new design called the “Differential Speed Regime” is proposed and evaluated experimentally to determine its effectiveness in enhancing device efficiency. To conduct the experiments, an experimental rig was built and installed in an iron pelletizing factory to replicate real conditions. The rig was tested with the production output of a real pelletizing disk. Based on the obtained experimental results, the effects of each introduced variable individually, as well as their cross-effects, were explored and discussed. The results showed that the proposed approach successfully improved screen efficiency. In this regard, the maximum attainable efficiency of the conventional roller screen is around 72%, whereas the proposed design achieves more than 82%. However, it was revealed that to attain maximum efficiency, the influential parameters need to be set at optimal values. For instance, to achieve the best efficiency, for deck angle of $6^\circ$ $6^{\circ}$ , the roller’s speed should be around 160 rpm while, for angles of $12^\circ$ $12^{\circ}$ and $18^\circ$ $18^{\circ}$ , it should be around 120 and 80 rpm, respectively.