How to Buy a Vibrating Screen: High-Frequency and Dewatering Solutions by TAPP Group

At one client’s coal preparation plant, production was on the verge of shutdown due to poor product dewatering. Fine coal with high moisture was entering the drying unit. Concentrate moisture reached up to 20%, and the dryer simply couldn’t evaporate that much water.
Initially, it seemed that the bottleneck was the drying section, and the only solution was to build a second dryer. However, TAPP Group engineers carried out a process audit and proposed replacing the outdated screen in front of the dryer with a modern dewatering vibrating screen specifically designed by TAPP Group for this task.
The dewatering screen uses high-frequency vibration to maximize moisture removal from the material. Operating at an acceleration of up to 20G, it breaks the capillary bonds between material particles, allowing water to be efficiently released.
For this coal preparation plant, installing the new dewatering screen achieved the following:

• Reduced moisture in the dryer feed from ~20% to ~12%, with final concentrate moisture at ~8%.
• Cut dryer load by 12 tons of water per hour (significantly reducing evaporation demand).
• Saved about 9,600 kWh of heat energy per hour (nearly 10 MW), equivalent to around 188,000 rubles in hourly savings.
• The drying system stopped being the plant’s bottleneck and began operating under stable conditions.
• Annual plant throughput increased from approximately 550,000 to 850,000 tons (+300,000 tons — equivalent to “building” half a new plant).

Later, inspired by this success, the company modernized other units as well (replacing key equipment with TAPP Group solutions) and reached about 940,000 tons per year. But the most dramatic breakthrough came from that single vibrating screen replacement.
The result demonstrates that the right vibrating screen can deliver a “quantum leap” in performance — and even save a plant from shutdown.

The global market today offers hundreds of vibrating screen models. Choosing the right one is not easy. With such variety, it’s important to remember that low price doesn’t mean high quality. A good solution must meet several critical criteria:

• Reliable materials and design. Structural components must have high strength, wear and corrosion resistance, and maintain these properties under low temperatures and outdoor conditions. For example, HUCK bolt hole drilling (instead of plasma cutting), properly designed cross beams (ideally round-section beams), and other quality details make a big difference.
• Professional design and customization. There are no universal solutions. It’s essential to choose the right type of vibrating screen, screening area, and deck configuration. The selection must account for all specifics of your production process and material characteristics.
• Service and warranty. By purchasing a vibrating screen from TAPP Group, you receive full service support, rapid on-site visits by service engineers, and prompt spare parts delivery.

TAPP Group specializes in the design and implementation of high-performance vibrating screens. We provide customized solutions tailored to each client’s operational requirements.
As the examples above show, a single targeted improvement can deliver colossal results — if it removes the main constraint. That’s why it’s worth starting not with large-scale changes, but with a professional plant audit to identify the true bottlenecks.