1. فتحة مدفوعة بنقطة الألم

هل تعاني عملية التعامل مع فحم الكوك من اختناقات مستمرة؟, توليد الغرامات المفرطة, وتكاليف الصيانة غير المخطط لها? يؤثر الفحص غير الفعال بشكل مباشر على أرباحك النهائية من خلال المنتج المفقود, زيادة استهلاك الطاقة للعمليات النهائية, ووقت التوقف المكلف لاستبدال سطح الشاشة. هل تواجه حاليا:

ترحيل الغرامات العالية: Ineffective separation leading to valuable coke breeze contaminating the product stream, reducing overall yield and saleable tonnage.
Frequent Screen Blinding & التوقف: Moisture and sticky fines clogging screen apertures, requiring frequent shutdowns for manual cleaning or deck replacement, إيقاف خط المعالجة بالكامل.
الإفراط في ارتداء المعدات: Uncontrolled vibration and impact from oversized material or poor feed distribution accelerating wear on screen panels, هياكل الدعم, and springs.
تصنيف المنتج غير متناسق: Fluctuating feed rates or improper screening action resulting in offspec product that fails to meet stringent customer or internal blast furnace specifications.
تكاليف تشغيلية عالية: The cumulative effect of these issues—lost production, ارتفاع تكاليف العمالة الصيانة, and premature component failure—erodes plant profitability.

The solution lies in specifying a vibration screen engineered explicitly for the abrasive, highimpact demands of coke classification. The right equipment transforms these operational challenges into controlled efficiency.

2. نظرة عامة على المنتج

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the precise size separation of metallurgical coke and coke breeze. Its primary function is to ensure a clean, onspec product while maximizing throughput and minimizing fines loss.

سير العمل التشغيلي:
1. تغذية تسيطر عليها: Sized coke from the crusher or cooler is delivered onto the screen via a regulated feed box to ensure even distribution across the full width of the screening surface.
2. HighIntensity Separation: A robust vibrator assembly (exciters or unbalanced motors) imparts a linear or elliptical motion to the screen box. This action stratifies the material, forcing undersize particles (نسيم فحم الكوك) through the defined screen panel apertures.
3. Positive Material Discharge: مادة كبيرة الحجم (فحم الكوك المنتج) travels along the deck length and discharges at the end of the screen, while undersize material is collected in a hopper beneath the decks for separate conveyance.

نطاق التطبيق & القيود:
This equipment is specifically designed for hot or cold coke sizing in coke handling plants, أنظمة شحن الفرن العالي, and anode production facilities. It is not suitable for wet screening applications without significant modification or for processing materials with drastically different bulk densities and abrasiveness without a full engineering review.

3. الميزات الأساسية

نظام دعم سطح السفينة الثقيلة | الأساس الفني: Reinforced crossmembers with bolted, modular panel attachment | المنفعة التشغيلية: Eliminates panel flexing and fatigue failure under heavy load; allows for rapid, individual panel replacement without welding | تأثير عائد الاستثمار: يقلل وقت التوقف عن تغيير سطح السفينة بنسبة تصل إلى 60% مقارنة بالأنظمة الملحومة.
تقنية سطح السفينة المضادة للعمى | الأساس الفني: Polyurethane or rubberclad screen panels with flexible, فتحات التنظيف الذاتي | المنفعة التشغيلية: Minimizes adhesion of moist fines; panels flex with each vibration cycle to dislodge trapped particles | تأثير عائد الاستثمار: Maintains consistent throughput and grading quality, reducing cleaning shutdown frequency.
DualVibrator Synchronization | الأساس الفني: Two externally mounted exciters synchronized via a gear coupling drive | المنفعة التشغيلية: Provides stable, linear vibration force across the entire screen box width; allows for easy adjustment of amplitude | تأثير عائد الاستثمار: Ensures uniform screening efficiency and extends bearing life through balanced load distribution.
SubResonant Spring Isolation | الأساس الفني: Screen box mounted on highcycle composite rubber springs or steel coil springs tuned below resonance frequency | المنفعة التشغيلية: عزلات تصل إلى 95% القوى الديناميكية من الهيكل الداعم; allows installation on elevated platforms without major structural reinforcement | تأثير عائد الاستثمار: Lowers installation costs and prevents vibration damage to surrounding infrastructure.
حزمة بطانة مقاومة للتآكل | الأساس الفني: Wear plates lined with AR400 steel at all critical impact points (صندوق تغذية, تفريغ الشفاه) | المنفعة التشغيلية: Protects the main screen body from direct abrasion by coarse coke | تأثير عائد الاستثمار: Extends structural life of the main asset by years, deferring major capital expenditure.
Enclosed Dust Sealing System| الأساس الفني: Continuous rubber sealing strips between decks and around access doors| المنفعة التشغيلية: Contains dust emissions at transfer points for a cleaner, safer working environment| تأثير عائد الاستثمار: Reduces housekeeping labor and aids in compliance with plant environmental standards.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة | حل شاشة اهتزاز فحم الكوك | ميزة (% تحسين) |
| : | : | : | : |
| عمر خدمة لوحة السطح | 36 شهور (الصلب القياسي) | 918 شهور (modular polyurethane/AR combo) | +100% ل +200% |
| كفاءة الفحص (for target size)| ~8590% | ثابت 9396% efficiency maintained over time due to antiblinding tech| +5% الربح المطلق |
| Annual Downtime for Screen Maintenance| 80120 ساعة / سنة (تنظيف & changes) | 3050 ساعة / سنة (modular changes only)| ~تخفيض بنسبة 60% |
| Vibration Transmission to Structure| بارِز; often requires stiffening| الحد الأدنى (90% isolation |
| Amplitude Adjustment Process| Requires adding/removing eccentric weights; downtime needed| External adjustment via variable counterweights or motor speed control; operational adjustment possible.| Time savings >75% per adjustment |

5. المواصفات الفنية

سعة & تصنيف: مصممة للإنتاجية من 50 الهيدروكربونات النفطية إلى 1,200+ TPH depending on model size and aperture selection.
متطلبات الطاقة: مدفوعة بمحركات هزازة مزدوجة تتراوح من 2 س 7.5 كيلوواط ل 2 س 45 كيلوواط (400/690V, 50/60هرتز). Drive motor requirements vary by model.
مواصفات المواد: Main frame Carbon steel (ST37). Wear surfaces Replaceable AR400 steel liners. Screen panels Modular polyurethane rubber tensioned panels OR perforated steel plate panels with abrasionresistant treatment.
الأبعاد المادية: أعزب, مزدوج, أو تتوفر تكوينات ثلاثية الطوابق. Typical widths from 1.2m to 3.6m; lengths from 4m to 10m inclusive of feed/discharge boxes.
نطاق التشغيل البيئي: مصممة لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +50 درجة مئوية. Handles material temperatures up to ~150°C continuously with appropriate component specifications.

6. سيناريوهات التطبيق

Blast Furnace Coke Screening Plant

Challenge A major integrated steel mill experienced excessive fines (<10مم) in their blast furnace feed stock due to degraded screenscreen decks blinding daily through moisture ingress causing inconsistent sizing that risked furnace permeability
Solution Installation of two tripledeck Coke Vibration Screens featuring selfcleaning polyurethane panels on top/middle decks combined with high open area wire mesh bottom decks
Results Achieved consistent product grading with <2% fines carryover eliminated two daily manual cleaning shifts reduced annual maintenance hours by over four hundred

Coke Breeze Recovery Circuit

Challenge An independent coke producer was losing significant revenue as valuable breeze was being misdirected into waste streams due an inefficient singledeck vibrating screen
Solution Implementation of a dedicated doubledeck fine Coke Vibration Screen equipped with specialized ball tray decks prevent blinding on fine mesh apertures
Results Recovered an additional metric tons per hour saleable breeze increasing annual revenue by over fifteen percent achieving full payback within eight months

Anode Grade Coke Sizing

Challenge A carbon plant required extremely tight particle size distribution control but their existing screens produced excessive attrition generating unwanted ultrafines during classification process
Solution Commissioning customengineered lowattrition linear motion Coke Vibration Screens featuring gentle material handling low stroke/highfrequency design combined cascading deck arrangement
Results Reduced generation minus fraction by thirty percent while meeting stringent topsize cut point specification improving downstream paste mixing consistency

الاعتبارات التجارية

Pricing tiers are primarily determined by machine size deck count features:
Base Model Tier Standard duty construction fixed amplitude vibrators conventional steel panels suitable lower capacity replacement applications
Performance Tier Includes antiblinding decks adjustable amplitude vibrators composite spring isolation extended wear linings recommended new installations major upgrades
Premium Tier Full custom engineering including special materials dust suppression hoods advanced monitoring sensors predictive maintenance integration

Optional Features Include spray systems dust encapsulation covers variable frequency drives remote monitoring kits different panel types access platforms walkways

Service Packages Available as factory commissioning multiyear parts kits annual inspection contracts full maintenance agreements ensuring operational readiness

Financing Options Flexible acquisition models include outright purchase capital lease operating lease structures tailored support project financing large capital projects

التعليمات

What is typical lead time delivery new Coke Vibration Screen?
Lead times vary based complexity customization standard designs typically available within weeks fully customized units may require months detailed engineering fabrication commence upon order approval

Can this equipment integrate existing conveyor feed system?
Yes screens are engineered accept standard belt conveyor feeds require properly designed feed box ensure even distribution across full width maximize efficiency prevent localized wear

How does power consumption compare older screening equipment?
Modern designs focus energy efficiency direct drive exciters premium efficiency motors typically result similar marginally lower consumption compared older units while delivering significantly higher throughput reliability

What key factors determining correct screen size my application?
Primary factors are total required tonnage per hour desired separation sizes percentage open area selected panels material bulk characteristics consultation application engineer essential specify correctly

هل قطع الغيار متوفرة بسهولة؟?
Manufacturers maintain comprehensive inventory critical wear parts vibrator assemblies springs panel modules ensuring availability minimize potential extended downtime events