Haver & Boecker Niagara Engineers the Largest Vibrating Grizzly Screen in the World

• Haver & Boecker Niagara has engineered the world's largest vibrating grizzly screen, the Niagara XL-Class, for a Brazilian iron ore operation.

• The Niagara XL-Class vibrating grizzly screen has a capacity of 8,000 tph and can handle a cut size of 200 mm, with the ability to screen material top sizes of 1.3 meters.

• Constructed with Hardox® steel, the screen is designed to remove large stones and relieve pressure on the primary crusher, enhancing production efficiency.

• The XL-Class is an exciter-driven machine, featuring a unique design with three exciters placed beneath each body due to the large particle sizes encountered.

• The screen's modular design, weighing 120 tons, was necessary to accommodate the large size and the specific requirements of the operation.

• Denilson Moreno, sales manager at Haver & Boecker Niagara, emphasizes the company's commitment to customizing solutions based on individual customer needs and operations.

• Haver & Boecker Niagara utilized their NIAflow plant simulation software to optimize the plant design and processes for the customer's specific goals and material.

• To ensure maximum uptime, the XL-Class screen is equipped with Haver & Boecker Niagara’s Pulse condition monitoring system, which uses sensors to monitor the machine's health and provide maintenance forecasts.

• The Pulse condition monitoring system offers real-time data, e-mail alerts for system anomalies, and insights into preventive maintenance to prevent unplanned downtime.

• Clayton Carvalho, managing director of Haver & Boecker Niagara’s Brazil operation, highlights the company's role as a consultant and partner with over 150 years of industry experience.

Haver & Boecker Niagara custom-engineers the largest vibrating grizzly screen in the world. Manufactured with Hardox® steel perforated plates and grizzly bars for a large Brazilian iron ore operation, the Niagara XL-Class vibrating grizzly screen boasts a capacity of 8,000 tph and a cut size of 200 mm. As the largest exciter-driven machine in the industry, the XL-Class provides the operation with high-capacity screening while maximizing uptime and production. Combined with the grizzly technology, the XL-Class offers the necessary ability to remove large stones, 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. With this customization, the 1.3-meter particles did not allow for the normal placement of exciters, resulting in adjusting the design to place three exciters beneath each body rather than the standard overhead location. Effectively screening material top sizes of 1.3 meters, the XL-Class grizzly vibrating screen removes oversized materials to relieve the crusher.

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“We recognize 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 realized to truly maximize 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 listened to the operation’s challenges and employed their signature NIAflow plant simulation software to address them. The software analyzed the proposed plans, processes, goals and material for plant optimization, providing information to the customer and Haver & Boecker Niagara to design and custom engineer the one-deck vibrating grizzly screen.

To maximize 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.”