شاشة اهتزاز فحم الكوك: HighCapacity Sizing Solutions for Metallurgical Coke Processing

التحدي التشغيلي: When Screen Reliability Becomes Your Bottleneck

Every ton of metallurgical coke that fails to meet size specifications represents lost revenue, عقوبات العقد, and downstream process disruption. Plant managers across the steel and foundry industries face the same recurring problems:

• التعمية والربط — Moisture content in quenched coke causes fines to adhere to screen media, reducing effective screening area by up to 40% within a single shift
• التعب الهيكلي — The abrasive, highimpact nature of coke handling causes premature failure of screen decks, with typical replacement cycles of 6–9 months under continuous operation
• تكاليف التوقف — Every hour of unscheduled screen downtime in a 1.5 MTPA coke plant translates to approximately $4,800 in lost production value, not including maintenance labor and replacement parts
• جودة المنتج غير متناسقة — Offspec coke fractions (كبيرة الحجم >75mm or undersize <25مم) trigger customer rejections and rescreening costs that erode already thin margins
• Vibration transmission — Poorly designed screen mounts transfer harmful vibrations to support structures, accelerating wear on conveyors and chutes

Your screening equipment must handle 200–300 tph of abrasive, hightemperature coke while maintaining separation efficiency above 90%. Can your current system deliver that consistently, shift after shift, without unscheduled interruptions?

نظرة عامة على المنتج: The Coke Vibration Screen

The Coke Vibration Screen is a heavyduty, linearmotion vibrating screen engineered specifically for the classification of metallurgical coke, فحم الكوك مسبك, and petroleum coke at capacities from 50 ل 400 tph. This equipment performs dry sizing of coke fractions at ambient or elevated temperatures (تصل إلى 120 درجة مئوية) without requiring water sprays or additional processing aids.

سير العمل التشغيلي

1. توزيع الأعلاف — Coke enters the screen through a feed chute, where an integrated distribution plate ensures even material spread across the full deck width, preventing localized overloading and maximizing screening efficiency
2. التقسيم الطبقي — The linear motion (amplitude 6–10mm, frequency 750–900 rpm) causes smaller particles to migrate downward through the material bed, establishing contact with the screen surface
3. فصل الحجم — Material passes over woven wire mesh or polyurethane panels with apertures from 10mm to 80mm, separating into oversize, متوسطة الحجم, والكسور الأصغر حجما
4. تسريح — Three independent discharge spouts direct each fraction to dedicated conveyors or storage bins, with optional dust collection hoods for environmental compliance
5. SelfCleaning Action — The combination of high acceleration (4.5–5.5 G) and specialized ball deck assemblies continuously clears apertures, maintaining open area throughout the shift

نطاق التطبيق

This screen is suitable for coke breeze recovery, فصل فحم الكوك (10–25mm), تحجيم فحم الكوك (25–80mm), and blast furnace coke classification. It operates effectively with feed moisture up to 12% (quenched coke) and feed temperatures up to 120°C. The equipment is not recommended for wet screening applications or for materials with more than 15% محتوى الطين.

الميزات الأساسية

HighG Linear Motion Exciter | الأساس الفني: Dualshaft counterrotating exciter generating linear vibration at 4.5–5.5 G acceleration | المنفعة التشغيلية: Aggressive stratification separates nearsize particles that typically cause inefficiency in circularmotion screens | تأثير عائد الاستثمار: Screening efficiency improves from industryaverage 85% to 93–95%, reducing recirculation loads by 30%

نظام سطح السفينة وحدات | الأساس الفني: Boltin polyurethane or wire mesh panels with quickrelease tensioning | المنفعة التشغيلية: Your maintenance crew can replace a worn deck section in 45 دقائق مقابل 4 ساعات للتصاميم الملحومة | تأثير عائد الاستثمار: Annual maintenance labor savings of $12,000–$18,000 per screen, زائد 15 additional operating hours per year

SelfCleaning Ball Decks | الأساس الفني: Rubber balls in pockets beneath the screening surface, activated by screen vibration | المنفعة التشغيلية: Continuous aperture clearing prevents blinding from moist coke fines, maintaining effective open area above 85% | تأثير عائد الاستثمار: Eliminates manual cleaning stops, recovering 2–3 hours of production per week

الإطار الهيكلي للخدمة الشاقة | الأساس الفني: S355J2 steel side plates (minimum 12mm thickness) with stressrelieved welded construction and finite element analysis validation | المنفعة التشغيلية: يتجاوز عمر خدمة الإطار 15 years under continuous 24/7 عملية, even with impact loading from feed chutes | تأثير عائد الاستثمار: Replacement cost avoidance of $45,000–$60,000 per screen over a decade

Adjustable Stroke and Angle | الأساس الفني: Exciter weights adjustable in 5° increments; screen inclination adjustable from 0° to 15° | المنفعة التشغيلية: Your operators can finetune retention time and bed depth to match specific coke moisture and size distribution changes | تأثير عائد الاستثمار: Optimized settings improve throughput by 8–12% without additional energy consumption

احتواء الغبار المتكامل | الأساس الفني: Bolted dust covers with rubber seals and optional negativepressure extraction ports | المنفعة التشغيلية: Meets EPA particulate emission standards (PM10 < 50 ملجم/م3) without external enclosure costs | تأثير عائد الاستثمار: Avoids $25,000–$40,000 in separate dust collection hood fabrication and installation

Vibration Isolator Mounts | الأساس الفني: Composite coil spring and rubber isolators with 95% vibration reduction efficiency | المنفعة التشغيلية: Transmitted dynamic forces to support structures are reduced to 5% of input, protecting adjacent equipment | تأثير عائد الاستثمار: Extends conveyor and chute life by 3–5 years, saving $8,000–$15,000 in structural reinforcement costs

المزايا التنافسية

| مقياس الأداء | معيار الصناعة | حل شاشة اهتزاز فحم الكوك | ميزة (% تحسين) |
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| كفاءة الفحص (at 50mm cut point) | 85-88% | 93-95% | 6-8% أعلى |
| Deck Replacement Time | 4-6 ساعات | 45–90 minutes | 60– 75% أسرع |
| Frame Service Life | 8–10 years | 15+ سنين | 50% أطول |
| التوقف غير المقرر (سنوي) | 120–180 hours | 40-60 ساعة | 60– تخفيض بنسبة 70% |
| Effective Open Area (after 8h operation) | 55-65% | 85-90% | 30–40% better |
| مستوى الضوضاء عند 1 متر | 95–100 dB(أ) | 85–88 dB(أ) | 10–12 dB(أ) أدنى |
| استهلاك الطاقة لكل طن معالج | 0.35-0.45 كيلووات ساعة/طن | 0.25-0.30 كيلووات ساعة/طن | 20–30% less |

المواصفات الفنية

| المعلمة | مواصفة |
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| نطاق النموذج | CVS15 (15 م²), CVS20 (20 م²), CVS25 (25 م²) |
| نطاق السعة | 50–150 tph (CVS15), 100-250 طن بالساعة (CVS20), 150-400 طن في الساعة (CVS25) |
| نطاق نقطة القطع | 10–80 mm (adjustable via deck configuration) |
| تكوين سطح الشاشة | 1, 2, أو 3 الطوابق (depending on fraction requirements) |
| تردد الاهتزاز | 750–900 rpm (قابل للتعديل عن طريق VFD) |
| السعة (سكتة دماغية) | 6–10 mm (قابل للتعديل) |
| تسريع | 4.5–5.5 G |
| Screen Inclination | 0° to 15° (قابل للتعديل) |
| قوة المحرك | 2 × 15 كيلوواط (CVS15), 2 × 22 كيلوواط (CVS20), 2 × 30 كيلوواط (CVS25) |
| الجهد االكهربى | 380V / 660V / 3مرحلة / 50Hz or 60Hz (مخصص متاح) |
| Side Plate Material | S355J2 الفولاذ الهيكلي, 12–16mm thickness |
| خيارات وسائط الشاشة | Woven wire mesh (mild steel or stainless), ألواح البولي يوريثين (80 شور أ), ألواح مطاطية |
| حجم التغذية (الحد الأقصى) | 150 مم |
| Feed Temperature (الحد الأقصى) | 120°C continuous |
| تغذية الرطوبة (الحد الأقصى) | 12% (quenched coke) |
| الأبعاد الشاملة (CVS20) | 6.5m L × 3.2m W × 2.8m H |
| الوزن الإجمالي (CVS20) | 18,500 كجم |
| نطاق درجة حرارة التشغيل | 10درجة مئوية إلى +50 درجة مئوية (المحيطة) |
| انبعاث الغبار (with covers) | PM10 < 50 ملجم/م3 |
| مستوى الضوضاء عند 1 متر | 85–88 dB(أ) |
| Vibration Isolation Efficiency | 95% |

سيناريوهات التطبيق

Integrated Steel Plant — Blast Furnace Coke Sizing | تحدي: أ 2.8 MTPA steel plant experienced 14% offspec coke (كبيرة الحجم >75مم) reaching the blast furnace, causing burden distribution problems and increasing coke rate by 18 kg/tHM | حل: Installation of two CVS20 screens in parallel, configured with 75mm top deck and 25mm bottom deck, يعالج 220 tph لكل منهما | نتائج: Offspec coke reduced to 3.5%, انخفض معدل فحم الكوك بنسبة 12 kg/tHM, وفورات في تكاليف الوقود السنوية $2.1 مليون, screen availability maintained at 96.5% زيادة 18 شهور

Foundry Coke Producer — Nut Coke Recovery | تحدي: A foundry coke producer was discarding 8,000 tpy of 10–25mm nut coke as waste due to inefficient screening, يمثل $640,000 in lost revenue annually | حل: Implementation of a CVS15 screen with polyurethane panels (10mm and 25mm apertures) and ball deck cleaning system | نتائج: Nut coke recovery increased to 92% of available material, توليد $590,000 in new revenue in the first year, فترة الاسترداد من 7 شهور

Coke Breeze Processing — Sinter Plant Feed | تحدي: A sinter plant required consistent 0–6mm coke breeze at 85 tph, but existing screens delivered only 68 tph with frequent blinding from 9% محتوى الرطوبة | حل: Deployment of a CVS15 screen with 6mm stainless wire mesh and highG exciter (5.2 ز) to overcome moisture adhesion | نتائج: زادت الإنتاجية إلى 82 tph (20% تحسين), moisturerelated downtime reduced from 14 ساعة / شهر إلى 2 ساعات / شهر, sinter plant productivity improved by 4.5%

الاعتبارات التجارية

طبقات التسعير

| إعدادات | نطاق السعر (دولار أمريكي) | Target Application |
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| معيار (CVS15, سطح واحد, شبكة سلكية) | $85,000– 110.000 دولار | Basic coke breeze screening |
| معزز (CVS20, سطح مزدوج, ألواح البولي يوريثين, يغطي الغبار) | $145,000–$185,000 | Blast furnace coke classification |
| غالي (CVS25, سطح ثلاثي, full dust containment, التحكم في VFD, المراقبة عن بعد) | $220,000– 280.000 دولار | Highcapacity integrated steel plants |

الميزات الاختيارية

• VFD Control Package ($8,500– 12000 دولار) — Enables frequency adjustment for variable feed conditions
• نظام المراقبة عن بعد ($6,000– 9000 دولار) — Realtime vibration, درجة حرارة, and bearing health data via Modbus or Profibus
• CeramicLined Feed Box ($4,500–$7,000) — Extends wear life in highimpact feed zones by 3×
• مجموعة قطع الغيار ($12,000– 18000 دولار) — Includes exciter bearings, الأختام, لوحات الشاشة, and tensioning hardware for 12 أشهر من العملية

حزم الخدمة

| طَرد | التغطية | التكلفة السنوية (دولار أمريكي) |
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| أساسي | 2 زيارات الصيانة الوقائية, دعم الهاتف, 48إرسال أجزاء الساعة | $9,500 |
| معيار | 4 زيارات الصيانة الوقائية, onsite repair within 24 ساعات, تسليم الأجزاء ذات الأولوية, تدقيق الأداء السنوي | $18,000 |
| شامل | Unlimited technical support, 12ساعة الاستجابة في الموقع, full parts inventory management, quarterly performance optimization | $32,000 |

خيارات التمويل

• الإيجار التشغيلي — 36–60 month terms with option to purchase at fair market value; دفعات شهرية من $2,400
• تمويل المعدات — 10–20% down payment, fixed rates from 6.5% أبريل, شروط تصل إلى 84 شهور
• العقد القائم على الأداء — Payperton processed with minimum throughput guarantee; ideal for contractors with variable production volumes

التعليمات

س: Can the Coke Vibration Screen handle feed material directly from a coke wharf without prescreening?

أ: نعم. The screen is designed to accept feed directly from wharf conveyors with lump sizes up to 150mm. The feed box includes an impactabsorbing liner and distribution plate that spreads material evenly across the deck. لكن, for feed containing >5% tramp metal or oversized lumps above 150mm, we recommend installing a grizzly or magnetic separator upstream to prevent deck damage.

س: ما هو الجدول الزمني النموذجي للتثبيت من الطلب إلى التشغيل؟?

أ: Standard delivery is 10–12 weeks from order confirmation. Site installation typically requires 5–7 working days with a twoperson crew, assuming prepared foundations and electrical connections. Commissioning and operator training add 2–3 days. For expedited projects, a 6week delivery option is available at a 10% تكلفة إضافية.

س: How does the screen perform with varying moisture content in quenched coke?

أ: البيانات الميدانية من 14 installations shows that screening efficiency remains above 90% for moisture content up to 10%. Between 10–12% moisture, efficiency decreases to 85–88%, which is still above industry average. The ball deck cleaning system prevents aperture blinding, but we recommend maintaining feed moisture below 12% للحصول على الأداء الأمثل. For consistently higher moisture, consider a predrying step or heated screen option.

س: What maintenance intervals should we plan for?

أ: Under continuous 24/7 عملية, the following schedule applies: exciter bearing inspection every 2,000 ساعات (replacement at 8,000–10,000 hours), screen panel inspection weekly (replacement every 6–12 months depending on abrasiveness), spring isolator check monthly (replacement at 3–5 years), and structural weld inspection annually. The comprehensive service package includes all scheduled maintenance, reducing your planning burden.

س: Can the screen be retrofitted into an existing screening station with different footprint dimensions?

أ: نعم. Our engineering team can adapt the base frame and support structure to match your existing foundation within ±300mm dimensional tolerance. We require a site survey drawing and structural assessment before manufacturing. Retrofit installations typically cost 8–12% more than new installations due to custom adaptation work.

س: ما هي تغطية الضمان المقدمة?

أ: يغطي الضمان القياسي 24 أشهر من التكليف أو 30 أشهر من الشحن, أيهما يحدث أولا. Coverage includes exciter assembly, لوحات جانبية, أعضاء متقاطعين, and vibration isolators. Screen panels and wear liners are excluded as consumable items. تتوفر خيارات الضمان الممتد حتى 60 months through the Comprehensive service package.

س: How does the energy consumption compare to our existing circularmotion screens?

أ: The linearmotion design is inherently more energyefficient. Measured consumption is 0.25–0.30 kWh per ton processed, compared to 0.35–0.45 kWh/t for comparable circularmotion screens. لتجهيز النبات 200 tph over 7,000 operating hours annually, this represents 140,000–280,000 kWh in annual savings, equivalent to $14,000–$28,000 at typical industrial electricity rates.

س: What is the lead time for replacement screen panels?

أ: Standard wire mesh panels are available from stock with 48hour dispatch. Polyurethane panels require 3–4 weeks manufacturing lead time. We recommend maintaining a spare set of panels for your critical deck (approximately $4,000–$6,000 depending on configuration) to eliminate downtime risk. Our parts inventory program can manage this automatically.