Derrick screens have been used in iron ore since the 1950’s processing all types of iron ore. From removing fine impurities in Direct Shipping Ore sinter products to scalping relatively coarse (+53 to 75 µm) middlings and size control in pellet concentrates. Some of the greatest benefits of fine screening have been achieved by replacing hydrocyclones in grinding circuits. The improved classification of fine screens results in a shift in the grind/grade relationship. In other words, a similar grade can be achieved at a coarser grind size or a higher grade at the same grind size compared to cyclone classification. Screen classification also allows for increase mill throughput that results in a lower power and steel consumption per ton. Fine screening can allow for lower grade ores to be processed more economically and can be used to produce higher grade and more valuable products. Typical operating cost is 1 to 2 US cents per ton and Returns On Investments for the capital costs are often measured in weeks.


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  • High capacity fine screening down to 45 µm (#325)
  • Minimal maintenance with long life urethane screen surfaces
  • Low power consumption – Derrick Dual SG Vibrators operate at 3 HP (2.2 kW)
  • Improved iron grade and reduction of impurities adding value to products
  • Increased iron recovery with less generation of ultra-fines in grinding circuits
  • Lower operating cost with savings in power and steel consumption in grinding circuits, less reagent consumption in flotation circuits, improved filtration
  • Compliments magnetic separation, gravity circuits, and flotation circuits with better size control
  • Recovery of fine iron from tailings
  • More consistent and higher value final product to meet customer demands


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Please note: Information on this website is subject to change. To obtain accurate dimensions and equipment configurations, please contact the Derrick Engineering Department for an updated GA drawing.


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Case Study 207 – Stack Sizers Improve Iron ore Classification by Replacing Hyrocyclones


Case Study 218 – Stack Sizers Improve Classification Efficiency, Lower Energy Cost in Second- Stage Grinding Circuit