H1: HighCapacity Custom Coke Vibration Screens for Precision Sizing and Scalping

1. PYNPUNT GEDREWE OPENING

Managing coke feedstock quality presents persistent challenges that directly impact downstream process efficiency and plant profitability. Stry jy met:
Sizing Inconsistencies: Variable feed leading to offspec product, causing rejections or penalties from blast furnace operators.
Oormatige boetes Generasie: Conventional screening methods contributing to excessive breakage of highvalue lump coke, eroding yield and revenue.
Onbeplande stilstand: Frequent screen cloth changes and structural fatigue from abrasive coke abrasion, resulting in costly production halts.
Scalping Inefficiencies: Inadequate removal of oven debris (silicon carbide, "oven stone") and oversized material, risking damage to crushers and conveyors.
Hoë Onderhoudslas: Laers, vere, and decks failing prematurely under heavy loads, driving up spare parts costs and labor hours.

If these operational costs are affecting your bottom line, the specification of your screening equipment is a critical leverage point. 'n Doelgerigte Custom Coke Vibration Screen is not merely a commodity filter; it is a core component for achieving grade control, protecting capital equipment, en die maksimum deurvloei.

2. PRODUK OORSIG

A Custom Coke Vibration Screen is a heavyduty vibratory screening machine specifically engineered for the dry separation and classification of metallurgical coke. Die ontwerp gee prioriteit aan duursaamheid, accurate particle separation, and highvolume handling in harsh environments.

Operasionele werkvloei:
1. Voer Inleiding: Raw coke from the quench car or storage is conveyed onto the screen's robust feed box.
2. Stratifikasie & Skeiding: A highenergy, linear or elliptical vibratory motion stratifies the material bed. Smaller particles pass through precisely sized screen deck apertures.
3. Fraksie ontslag: Correctly sized lump coke discharges from the deck end as product. Undersize (coke bries) passes through to a separate collection chute. Oversize material or scalped debris exits via a dedicated reject spout.

Toepassingsomvang & Beperkings:
Omvang: Primary sizing of hot or quenched metallurgical coke, scalp removal of oven debris (SiC), ontstof (briesie verwydering), and routing of multiple product fractions. Suitable for sinter plant feed preparation.
Beperkings: Not designed for wet screening applications or for materials with high moisture content that causes blinding. Maximum capacity is defined by physical aperture size and material bulk density.

3. KERNKENMERKE

Modulêre dekstelsel | Tegniese basis: Independently tensioned panel frames | Bedryfsvoordeel: Allows for rapid replacement of individual screen sections without full deck shutdown | ROI impak: Verminder instandhoudingstyd met tot 60% per omskakeling

Skuurbestande voeringpakket | Tegniese basis: Bolton AR steel plates in highwear zones (voer boks, ontslag lippe) | Bedryfsvoordeel: Beskerm strukturele staal teen slytasie, extending mainframe service life by multiples | ROI impak: Eliminates costly structural repair campaigns; defers capital replacement

HeavyDuty spoelveer-isolasie | Tegniese basis: Progressiverate steel coil springs | Bedryfsvoordeel: Absorbs dynamic loads while transmitting minimal vibration to the support structure | ROI impak: Reduces foundational stress cracks and associated civil maintenance costs

Centralized Greasing Lube System | Tegniese basis: Manifold with lines to all bearing points | Bedryfsvoordeel: Ensures consistent lubrication of vibrator shaft bearings under high thermal stress | ROI impak: Extends bearing service life; prevents catastrophic failure causing extended unplanned downtime

Variable Amplitude & Frequency Drive | Tegniese basis: Adjustable eccentric weights & VFD motor control | Bedryfsvoordeel: Operators can tune screen motion for optimal stratification with varying feed rates or coke characteristics | ROI impak: Maintains screening efficiency across shifts, maximizing consistent product yield

4. MEDEDINGENDE VOORDELE

| Prestasie-metriek | Nywerheid Standaard Oplossing | Pasgemaakte Coke-vibrasieskermoplossing | Voordeel (% Verbetering) |
| : | : | : | : |
| Skermdoeklewe (Lump Deck) | Standard woven wire mesh | Reinforced polyurethane panels with steel backing grid | +150200% lewensduur |
| Draende MTBF (Gemiddelde tyd tussen mislukking) | ~8,000 hours in harsh service | >12,000 hours with specialized sealing & lube systems| +50% operational reliability |
| Screening Efficiency at 80mm cut point| ~8590% efficiency| Konsekwent >94% efficiency via optimized throw & angle| +59% more product on spec |
| StructureBorne Vibrations Transmitted to Support| Significant harmonic vibration observed| Isolated via tuned spring system & subframe design| Vermindering van >70% measured vibration |
| Totale koste van eienaarskap (5jaar tydperk)| High consumable & repair costs| Predictable maintenance schedule with protected structure| Gedokumenteer 2535% laer TCO |

5. TEGNIESE SPESIFIKASIES

Kapasiteitgradering: Modelle van 500 TPH aan 2,500+ TPH capacity for metallurgical coke (grootmaatdigtheid ~0,5–0,7 t/m³).
Kragvereistes: Driven by 15 kW aan 45 kW vibratormotors (depending on size), standard 400/690V AC supply.
Materiaalspesifikasies: Mainframe constructed from heavyduty S355JR steel; critical wear areas lined with Hardox 400/500 of ekwivalente AR-plaat; corrosionresistant paint system.
Fisiese afmetings: Single or doubledeck configurations; typical deck widths from 1.8m to 3.6m; lengtes van 4,8m tot 7,2m.
Omgewingsbedryfsreeks: Ontwerp vir omgewingstemperature van 20°C tot +50°C; capable of handling hot coke up to ~200°C with heatresistant components.

6. TOEPASSINGSSCENARIO'S

Integrated Steel Plant Blast Furnace Feedstock Preparation

Uitdaging: A major mill faced inconsistent blast furnace performance linked to variable coke size distribution and periodic contamination from oven debris.
Oplossing: Installation of a primary scalping Custom Coke Vibration Screen with a coarse top deck for debris removal and a lower sizing deck.
Resultate: Achieved consistent lump coke sizing (>80mm) met <2% oversize/undersize variability; eliminated downstream crusher damage events; aangeteken a 1.5% reduction in blast furnace coke rate within one quarter.

Merchant Coke Producer Yield Optimization

Uitdaging: The client's existing screens generated excessive fines (10mm breeze), converting highvalue lump product into lowerrevenue streams.
Oplossing: Implementation of a twindrive Custom Coke Vibration Screen featuring polyurethane decks designed for reduced abrasioninduced breakage.
Resultate: Fines generation reduced by an average of 18%; lump coke yield increased correspondingly, directly boosting annual revenue by an estimated $1.2M at prevailing market prices.

7 KOMMERSIËLE OORWEGINGS

Equipment pricing tiers are determined by size/capacity (deck surface area), materiaal spesifikasies (standard vs premium AR linings), dryfkonfigurasie (single vs dual), and control sophistication (basic vs PLCintegrated).

Opsionele kenmerke:
Dust encapsulation hoods
Aircooled vibrator units
Gevorderde toestandmoniteringsensors (vibrasie/temperatuur)
Vlekvrye staal komponente vir hoogs korrosiewe omgewings

Service packages typically include:
Extended warranty plans covering bearings and structural integrity
Jaarlikse inspeksie & vibrasie analise programme
Onsite training for operation & voorkomende instandhouding

Financing options available include capital purchase through project finance partners or longterm operating lease agreements designed to preserve capital budgets.

8 Gereelde vrae

Q1 Are your screens compatible with existing conveyor layouts?
A1 Our engineering team designs custom feed boxes discharge heights based on your specific layout drawings ensuring seamless integration into your current transfer points

V2 Wat is die verwagte impak op my algehele plantgeraasvlakke?
A2 Field data shows our fully isolated designs typically operate below dB(A) levels specified by most industrial health standards reducing noise pollution concerns

Q3 How does this solution address screen blinding issues common with sticky materials?
A3 While primarily dry screens we offer optional deck heating systems ball tray decks antiblinding devices tailored if minor moisture is present

V4 Wat is tipiese deurlooptye?
A4 Lead times vary based on complexity Standard configurations require weeks while fully customized units require weeks following finalized engineering approval

V5 Kan u prestasiewaarborge verskaf?
A5 Yes we provide contractual guarantees on throughput capacity screening efficiency based on agreedupon feed material analysis

Q6 What spare parts inventory do you recommend?
A6 We provide a critical spares kit recommendation list including tensioning hardware specialized gaskets drive belts ensuring minimal waiting time for common wear items