Toquepala-Case-Study

This article reviews how Toquepala Mine addressed a screening challenge using Polydeck screen media solutions.

The Challenge

24% screen plugging was reducing effective open area and mill feed quality.

The issue highlights why a screen’s available openings matter alongside its nominal aperture size. When openings are obstructed, the useful screening area is not the same as the area specified for clean panels.

The Solution

Polydeck reports a media-only retrofit using POLYDEX MAXI on the top deck and RUBBERDEX on the bottom deck, retaining the frame and stringers.

Results

• Plugging reduced from 24% to 6.4%.
• Undersize throughput increased by 3%.

These are project-specific results reported by Polydeck, not a performance promise for another installation.

Key Lessons

For South African mining operations, this case provides a useful starting point for application-specific discussion rather than a ready-made specification. The following are general considerations, not additional reported Toquepala outcomes:

• Media selection: consider the duty of each deck instead of assuming one panel configuration suits the whole screen.
• Open area and throughput: discuss usable open area alongside the required separation and the undersize flow needed by the downstream process.
• Blinding and plugging: distinguish the observed obstruction mechanism before comparing media options; the terms should not be treated as interchangeable.
• Maintenance: include inspection access, cleaning needs and panel replacement in the application review. No maintenance saving is claimed for this case.

Any proposed configuration needs technical review against the actual material, screen and process requirements. This article does not describe a Carmaky project or a South African deployment.

Case source: Polydeck’s published Toquepala success story.

Read the Original Polydeck Success Story

Explore Carmaky’s screen media offering and Screen Media Guides.