Bilfinger Water Technologies
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JOHNSON INDUSTRIAL SCREENS
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JOHNSON SCREENS®:
AN OVERVIEW
INNOVATIVE DESIGN
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Bilfinger’s brand of Johnson Screens® specialises in
the design and manufacture of stainless steel filter
elements for liquid/solid and gas/solid separation.
Our screens are known for great strength, long
service life and a very high level of adaptability for
high-efficiency liquid/solid separation.
Johnson’s screens are made by welding vee-shaped
wire on support rods, creating slots which enlarge
inwardly, meeting the most demanding standards
for ruggedness, durability, consistency and slot
openings. The vee-shaped opening allows only two
contact points with the particles, thus preventing
any risk of clogging.
CUSTOM DESIGNED AND ENGINEERED
Each project is designed to ensure complete
satisfaction. We provide guidance and support from
project conception to completion.
LONGER LASTING
Johnson’s manufacturing standards are the most
stringent in the industry. Featuring the Vee-Wire®
technology, the screens are extremely durable and
have high resistance to abrasion, corrosion and
impact damage.
LESS COSTLY
Superior operating efficiency, reduced maintenance
needs and extended service life combine to decrease
the cost of Johnson’s screens to plant operators.
MANY CONSTRUCTION OPTIONS
Johnson’s screen surfaces can be used:
• For direct screening
• As filter media support (sand bed, activated
carbon, resins, catalysts)
Screens are available in slot opening from 25 µm
up to 25 mm. Most common materials used are the
300 series stainless steel, but many exotic alloys are
available to suit specific applications.
Screens are available in a variety of shapes to suit
customer needs:
• Cylinders
• Flat or curved panels
• Cones
• Any form specific to a given application
The flexibility of the process allows the
manufacture of custom made screens for all types of
applications: new plant, expansions or upgrades.
LOWER MAINTENANCE
The rugged construction and high quality of the
materials produce a product that lasts longer and
requires less maintenance.
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A HIGHLY TECHNICAL PRODUCT
MANY AREAS OF SCREEN APPLICATION
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The design and manufacturing characteristics of Johnson’s
screen surfaces provide the following advantages:
The strength, precision and design flexibility that characterise
our screens makes them the choice in a broad range of
industries and applications.
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Non-clogging surface
Large open area
Low pressure drop
Hydraulic efficiency
High flow rates
Mechanical strength
Abrasion-resistant
Easy cleaning
MARKET/INDUSTRY
• Water and waste water
• Pulp and paper
• Chemical
• Petrochemical
• Water supply
• Mineral and aggregate processing
• Plastics extrusion
• Machine coolant filtration
• Architectural applications
If your process involves any aspect of fluid/solid separation,
we have the products and experience to help you achieve
maximum efficiency and effectiveness.
APPLICATIONS
• Separating
• Filtering
• Media retention
• Sizing
• Dewatering
• Classifying
• Straining
• Drying
• Water intake
• Fish diversions
• Collection
QUALITY
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The Johnson Screens® brand has been delivering high quality
screens to various industries for more than a century; and
though technology has changed, our commitment to quality
products and services has not.
Bilfinger is an ISO-certified company; each product is subject to
a procedure of self-inspection by each operator throughout the
manufacturing process. A final inspection guarantees delivery
of a product that fully meets the user’s technical specification.
Bilfinger can provide the following documents upon request:
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Quality plan
Manufacturing plan and production schedule
Process qualification record (PQR)
Welding procedure specification (WPS)
Welder performance qualification (WQR)
In-house inspection reports / material certificates
Chemical and/or mechanical analysis certificates
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CYLINDRICAL SCREEN FOR OUTSIDE →
INSIDE FILTRATION
STANDARD
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External circumferential wire and
axial internal support rods.
Benefits:
• Economical
• Suitable for most applications
• Precision openings
•
Products:
• Filter cartridges
• Candle filters
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• Header laterals
• Rotating drum screens
• Nozzles
• Resin traps
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EXTERNAL AXIAL WIRE
(re-rolled)
CHANNEL ROD
CONSTRUCTION
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External axial wire with internal
circumferential support rods.
Perforated U-section channels
replace the internal support
rods. When the filter is used as a
collector, flow is outside-in. When
it is used as a distributor, flow is
inside-out.
Benefits:
• Facilitates cleaning with an
external axial-movement
scraper
Products:
• Automatic filters
Benefits:
• Optimised collection and distribution
• Replaces perforated inner tube
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Applications:
• Potable water treatment
• Ion exchange
• Oil refining processes
CYLINDRICAL SCREEN FOR INSIDE →
OUTSIDE FILTRATION
INVERTED
INTERNAL AXIAL WIRE
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(wire-base)
INTERNAL CIRCUMFERENTIAL
WIRE (re-rolled)
External circumferential inverted
wire and axial internal support
rods.
Internal axial wire with external
circumferential support rods.
Internal circumferential wire with
external axial support rods.
Benefits:
• Smooth internal screen surface
• Facilitates cleaning with an internal axial-movement
scraper
• The flow moves across the wire edges for effective dewatering
Benefits:
• Smooth internal filter surface
• Custom inner diameter
Benefits:
• Economical
Applications:
• Inside-out flow
Products:
• Screw press
Products:
• Trommel screens with internal feed
• Systems with an internal rotor or screw
• Dewatering systems
• Baskets
• Automatic filters
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PRODUCTS
FLAT SCREENS
CANDLE FILTERS
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Bilfinger offers a variety of flat screens
for the malting and brewing industries.
These Johnson Screens® Vee-Wire® screens are
ideal for:
The filtration capacity can be modified easily
by varying the number of candle filters to
obtain the required filter area. Johnson Screens®
Vee-Wire® candle filters are used widely in the
brewing industry for filtration. Housed inside a
cylindrical vessel, the filtration capacity can be
modified easily by varying the number of candle
filters to obtain the required filter area. Features
include:
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Lauder tubs
Germination
Kilning
Ultra filtration
Steeping
Malt extraction
Used in the kilning, germination and drying
phases of the malting process, Johnson Screens®
malting bed screens are the ideal choice for
malting floors and other screening needs in the
malting process.
• Small diameter usually less than 50 mm
• Substantial length usually greater than 1,000
mm
• Very fine openings: 25 to 150 µm, according to
the application
► IMAGE 02
These screen panels can be designed to
minimise “dead spots” in the malting floor, over
supports or other structures, to further improve
the overall process. In between malting batches,
the screens are very easy to clean, reducing
contamination during the process.
► IMAGE 01
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SUPPORT GRIDS
OUTLET BASKETS
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The support grid system is available in an
assortment of framing options and designs - as
a one-piece construction or in multiple sections
for on-site assembly and ease of retrofitting
through existing manways. Because of their
strength, durability and flow characteristics, our
support grids are widely used in hydrotreaters,
desulfurizers, molecular sieves, gas sweeteners,
ion exchangers and other absorption systems.
A large range of industries use cartridges.
Rugged, precise and easy to clean, these filter
elements are suitable for all industrial processes.
Benefits
• Self-supporting structure
• Exceptional resistance to collapsing or
buckling, even in operations where screens
must withstand extremely high loads
• More effective open area than grids using
wire mesh or grating
• Smooth surface of the screens reduces
abrasion of media
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Features
• Slot size can be designed for direct media
retention
• Grids can be supplied with support beams,
rope packing, bolting and all necessary
accessories
They can be used for:
• Conventional filtration, outside-in
• Reverse filtration, inside-out
The use of extremely fine wire maximises the
open area. This process is all the more true for
slots smaller than 100 microns.
The following types of fittings can be welded
to allow incorporation of cartridges into any
process:
• Collars
• Flanges
• BSP or NPT threaded end fittings
• Machined rings for fittings with O-rings or
flat baskets
• Other fittings
► IMAGE 04
► IMAGE 03
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JOHNSON SCREENS®
CENTRIFUGE BASKETS
CONTINUOUS CENTRIFUGE BASKETS
- STARCH PROCESSING
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Bilfinger’s Johnson Screens® starch baskets are custom made to fit into any existing or new
centrifuge application. They improve starch refining by providing accurate and customised slot
sizes, specific to your needs. Features of this basket include:
• Increased fibre dewatering compared to nickel screens
• Extended wear life
• Custom manufactured to each centrifuge design
• Variable slot openings from 20 μm and up
• Fine Johnson Screens® Vee-Wire® construction prevents clogging
• Capable of withstanding high backwash pressures
CONTINUOUS CENTRIFUGE BASKETS
- SUGAR PROCESSING
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Johnson Screens® patented fine Vee-Wire® continuous centrifuge basket is guaranteed to provide a
high mechanical strength, a precise slot opening and a larger percentage of open area, increasing the
amount of sugar crystal recovery.
The self-supporting structure of the basket is designed and engineered to withstand the high
stresses and load conditions of the sugar industry. Features of this basket include:
• Replaces electroformed and laser screens
• Variable slot openings from 20 μm and up
• Long lasting, fewer change-outs
• High resistance to abrasion
• Fast and easy installation
• Low maintenance, easy to clean
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PRODUCTS
NOZZLES
Benefits
SCREW PRESSES
& SCREW PRESS BASKETS
• P
revents expensive resin/media loss into
piping distribution system
• Protects
downstream
pumping
Nozzles are used in liquid/solid or gas/Bilfinger’s unique
modular
design drainer
screw press
equipment
solid separation. Their design and quantity
offers a single drive
solution for conveying, washing,
• Vpressing
isibility of minor
resin/media
losses
will vary depending on application and
dewatering and
solids for
the removal
of in
prevention
of
major
equipment
failure
customer-flow requirements. Nozzles allow
free water. This screw press has separate washing and
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a more effective use of the treatment media.
dewatering zones and reduces water content of the solids
Features
up to four times.
• Continuous slot design, allowing traps
Common applications include:
to capture
media
particles
ofthat
anyare
size,
• Collectors and distributors installed Bilfinger manufactures
screw
press
baskets
providing
open
to of
letscrew
to fit intosufficient
any make
andarea
model
uniformly across a plate or a header custom designed
process flow move smoothly
lateral arrangement
press.
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Stainless steel construction (other alloys
• Demineralizers, water softeners and in
can be includes
used depending
on pressure
and
pressure and gravity sand filters
The variety of baskets
high strength,
Johnson
temperature)
Screens® Vee-Wire®
and drilled hole slotted designs,
Various options
for sizes,
shapes
and
Benefits
which provide• increased
open area,
enhanced
fibre
connections,
depending
• Economical design
retention and improved
effluent
clarity. on process flow
characteristics
► IMAGE 05
• Non-plugging design
• Designed for full system pressure
• High open area
• Increased strength & corrosion resistance
► IMAGE 07
120° SIEVE BEND SCREENS
SCREEN LATERAL SYSTEMS
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Features
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• Standard diameter: 50 mm
Johnson
• Typical slot opening ranging from 0.2
mm Screens® 120° sieve bend screens are used in
These
assemblies
consist
of a series ofAs
static sieves for
either
dewatering
or classification.
to 0.5 mm
screen
connected
either amade
central
the slurry flows
overlaterals
the inclined
screentosurface,
of
• Threaded end fittings or “L” bolts
header
pipe or a hub.
Theya are
designed
perpendicular
to flow,
layer
of slurryfor
is
• Primarily made of stainless steel; wires which are
sliced away. effective media retention in a wide range of
however, special spherical nozzles made
applications, including ion exchangers, clay
from ABS or Kynar® are also available
and
sand filtration
and carbon
► IMAGE 05
Made from our
patented
Johnsonapplications
Screens® Vee-Wire®
towers.
screens, the 120°
sieve bend screens can provide up to 50
RESIN TRAPS
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percent more open area because of our greater range of
narrower wireBenefits
profiles.
• The design allows
a uniformBilfinger
collection
A resin trap is a safety device used on the
Considering manual-handling
restrictions,
or distribution
flow of
a gas orThe
liquid
overflow lines of ion exchange units, highdeveloped an innovative
split-sieve
concept.
design
treatment
media
without
purity water systems, activated carbonoffers
and a simple, through
economical benefit by reducing thedead
zones
media filters.
physical size and also the screen weight.
• The system can accommodate a wide
variety
of vessel
sizes and
shapes with
In many systems, a valve failure can allow
Features of the 120°
sieve
bend screen
include:
side, centre, top or bottom inlet piping
media to escape from the treatment vessel.
• The assemblies
can be designed
to
Not only is the loss of expensive media• Reduced equipment
and installation
costs
accommodate
flow in any direction
significant, but damage can easily occur
• to
Low maintenance
costs
downstream pumping equipment.
• Better flow rate and finer fibre removal
• Wide range of applications
Johnson’s resin traps, placed inline, provide
• Longer lifetime
positive protection. The traps can be • Slot sizes range from 25 μm to 10 mm
designed to capture media particles of •any
Typically made with 300 series stainless steel
► IMAGE 07
size.
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Features
• Lateral spacing, length, diameter and slot opening
sizes are based on individual system needs: slot
size 0.05 mm and up in 0.01 mm increments, and
diameter from 20 mm up
• Assemblies are typically made with type 304SS,
316LSS or other exotic alloys
• Connections of the laterals can be threaded fittings,
couplings or flanges
through the system. The slurry is gravity fed to the
head box and then flows to the screen. The solids
retained from the screen gather for disposal or reuse.
These easy-to-install gravity screens feature low
operating and maintenance costs. The Bilfinger
team of engineers can customise according to client
specifications.
► IMAGE 08
► IMAGE 06
FRACTAL COLLECTORS & DISTRIBUTORS
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Johnson Screens® gravity screens are typically
applied to make coarse separations ahead of
additional processing systems. The system uses a
Johnson Screens® Vee-Wire® dewatering screen
to retain the solids while allowing effluent to run
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PRODUCTS
120° SIEVE BEND SCREENS
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Johnson Screens® 120° sieve bend has a greater screening
capacity than a flat screen due to forces exerted as material flows
against the curved surface. This curved profile wire screen is
mounted in a frame with the screen openings perpendicular to
the flow.
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In a typical feed situation, the leading edge of the wedge wire
removes the water and fine particles through the screen up to
the cut point size, as the oversized particles move across the top
of the screen.
Separation size is considerably smaller than screen openings,
usually about one-half the opening size.
Sieve bend screens are ideal for sizing and dewatering
applications in liquid/solid separation situations. It is
extensively used for fine fibre removal in the starch industry. It
also is used in other industries such as food processing, waste
water cleanup and corn wet milling.
Features of the Johnson Screens® 120° sieve bend screen include:
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Reduced equipment and installation costs
Low maintenance costs
Better flow rate and finer fibre removal
Wide range of applications
Longer lifetime
Slot sizes range from 25 μm to 10 mm
Typically made with 300 series stainless steel
► IMAGE 07
CYLINDRICAL BASKETS
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Cylindrical baskets can be designed for a flow from out to in
(standard construction) or from in to out (re-rolled construction).
They screens are adapted for self-cleaning filters or screw press
filters and can be cleaned with static scrapers.
Benefits
• Self cleaning surface
• High open area
• Strong construction
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Features
• Dimensions adaptable to any specific needs
• Large range of constructions (wires, rods)
• All slot sizes from 25µm
• Flanges and reinforcement rings available depending on the
application
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► IMAGE 12
PRESSURE SCREENS
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Pressure screens are mainly used for the stock preparation in the
pulp and paper industry. They can be used for any application
regarding fibre or fine grain filtration.
Benefits
• The continuous slot gives a greater performance thanks to a
higher open area
Features
• Specific, contoured wire shape
• Diameters from 200 mm to 1,500 mm
• Increased screening efficiency
• Special surface chroming process allows for less frequent cylinder
replacement
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SCREW PRESS
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For dewatering using a screw press, Bilfinger can provide a screen
designed to meet your exact specifications. Our high-strength design
can withstand the rugged operation while providing an accurate
slot width and maximising open area to maximise dewatering. For
use in numerous industrial designs. Abrasion resistant options are
available.
Benefits
• High-strength design
• High open area
Features
• Accurate slot width
• Custom designed to fit any application
► IMAGE 13
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TECHNICAL DATA
STANDARD WELDING CONSTRUCTION
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Bilfinger’s standard welded construction uses resistance-welding
in a continuous elliptical motion to join the wire and rods. The
resistance welds the continuous length of wire to the rods as it
circulates.
Corner
Radius
Wire
Width
Slot
Wire
Height
Relief
Angle
Weld Penetration
Screens can be made in various formations, including cylindrical,
Support Rod
flat, or curved. Any variation of wire and rod sizes as well as slot
Height
opening can be chosen to develop the exact screen of your choice.
Screens are available in slot opening from 25 μm up to 25 mm. Most
common materials used are 300 series stainless steel, but many exotic alloys are available.
Screen
Height
WIRE AND RODS INFORMATION
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A wide range of wire and rod shapes make it possible to achieve the optimum balance of strength, open area, abrasion resistance
and dewatering/separation efficiency.
JOHNSON SCREENS® ROUND AND STRIP SUPPORT RODS
Round rods are available in diameters ranging from 3.2 mm to 12.7 mm. Strip rods are available in widths
from 1.8 mm to 4.8 mm and heights ranging from 9.5 mm to 50.8 mm.
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COMMON JOHNSON SCREENS® SHAPED
SUPPORT RODS
Our shaped support rods range in widths
from 0.7 mm to 3.8 mm and heights ranging
from 2.6 mm to 3.0 mm.
Q25
63
93
XJR
156
SR250
SR475
OPEN AREA CALCULATIONS
To calculate the open area of a certain screen, use the simple formula provided:
Open area (%) = Slot size * 100
Slot size + Wire width
JOHNSON SCREENS® VEE-WIRE® PROFILES
Bilfinger’s Johnson Screens®
Vee-Wire® profile wires range in
widths from 0.5 mm to 5.0 mm and
heights ranging from 1.0 mm to
9.0 mm. Other wire shapes are also
available.
20 30
47
63
69
93
118
130
191
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EXCEPTIONAL PRODUCTS,
EXCEPTIONAL SERVICE
FIELD SERVICE
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Bilfinger offers a complete field service activity with a team of specialised and experienced
supervisors available for various interventions like:
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Full installation
On-site repairs
Technical assistance or expertise
Work supervision
Inspection
Flexibility and expertise allow us to propose this extended scope of services under tailor-made
contract conditions in order to better serve our clients’ requirements.
Our experienced welder/fabricators team is available for onsite installation, repairs and screen
replacement for emergency situations or scheduled as needed.
Able to evaluate the condition of screens and make recommendations as to the best course of
action, our field service team will be there to allow the screens to operate at maximum capacity.
Whether cleaning, making minor or major repairs, or doing a complete replacement of screens, our
technicians are equipped with all the tools, equipment and experience needed to provide the best
field service available.
Our experienced technicians are also available for supervision of installations and on-site repairs.
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Bilfinger Water Technologies
General Industrial Business Unit
Australia
Phone +61 7 3867 5555
Fax +61 7 3867 5566
asiapacific.water@bilfinger.com
www.water.bilfinger.com
Quality
ISO 9001
Copyright ©2014 All rights reserved to Bilfinger Water Technologies Pty Ltd
01 _1013.00