Conventional spray bars often underperform in high-vibration, high-impact environments such as trommels, scrubbers, and ball mills. Simaflex Engineering’s flexible spray modules are designed to maintain effective coverage inside turbulent zones, improving mineral classification and reducing system failures.
The Problem with Rigid Spray Bars in Turbulent Zones
- Bending or breakage under impact from oversize
- Misaligned spray angles caused by vibration
- Undersprayed areas due to deflected or sagging bars
- High maintenance requirements and unscheduled shutdowns
Rigid spray bars were not designed for dynamic classifiers — and their failure leads to lost recovery and rising costs.
Flexible Spray Modules: Designed for Turbulent Classifiers
Simaflex’s spray solution incorporates:
- Flexible hoses that deflect and self-correct under impact
- Durable construction for abrasive and chemically harsh slurries
- Mounting systems that retain alignment in vibration-prone areas
- Modular design adaptable to screens, trommels, and mills
These upgrades make it possible to apply water where it’s most needed — directly inside the ore stream — without damage or misalignment.
Application Examples
- Trommel wash systems
- Scrubber spray lines
- Ball mill discharge chutes
- High-vibration screening decks
This technology eliminates the trade-off between spray system reliability and effective water placement.
Classification Improvements from Targeted Spraying
- Increased fines liberation and recovery
- Reduced recirculation of scats and oversize
- Cleaner screening surfaces
- Lower risk of oversize carryover and misclassification
By maintaining spray coverage inside turbulent zones, Simaflex spray modules contribute directly to throughput and product quality.
Results from Field Use
One mine trialled Simaflex spray modules in its assets and observed:
- Over 50% increase in spray system life
- Lower misclassification rates
- Reduced labour hours for spray bar repairs
- Decreased water demand per tonne processed
These outcomes were achieved without altering pump size or increasing system pressure.
Retrofit or New Installation Compatibility
Simaflex flexible spray systems can be installed as:
- Drop-in replacements for rigid bars
- Upgrades during shutdowns or planned maintenance
- Integrated designs for new circuit construction
All components are engineered for high-availability sites and modular installation.
Request an Engineering Review
Contact Simaflex Engineering to evaluate whether flexible spray modules are a fit for your classification circuit. Our engineering team can model coverage, pressure drop, and nozzle configuration to match your process needs.
Suggested Visuals
- Side-by-side diagram: rigid vs flexible spray bars in trommel
- Classification process schematic showing spray zone coverage
- Case study snapshot: service life comparison and recovery data