1. فتحة مدفوعة بنقطة الألم

Is your coke handling operation struggling with persistent bottlenecks and hidden costs? The screening stage is often a critical failure point, directly impacting downstream process stability and final product revenue. وتشمل التحديات المشتركة:

توليد الغرامات المفرطة: Inefficient or aggressive screening action degrades premium coke into lowvalue fines, eroding profit margins with every ton processed.
التوقف غير المخطط له: Screen deck blinding and premature wear on components like screen cloths lead to frequent, costly stoppages for maintenance and cleaning.
Inconsistent Product Grading: Variability in cutpoint accuracy results in offspec material, causing rejections from blast furnace operators or requiring costly rehandling.
تكاليف تشغيلية عالية: Constant component replacement, high energy consumption from inefficient drives, and laborintensive manual clearing directly increase your cost per ton.

Are you seeking a screening solution that prioritizes product integrity, maximizes uptime, and delivers a measurable return on investment? The reliability of your entire coke handling line depends on the performance of this single unit.

2. نظرة عامة على المنتج

This content details our engineered Coke Vibration Screen solutions, manufactured under contract to the highest specifications for demanding industrial applications. This equipment is a heavyduty linear or elliptical motion vibrating screen designed for the precise sizing and scalping of metallurgical coke and similar carbon products.

سير العمل التشغيلي:
1. مقدمة الأعلاف: Sized coke from the crusher or coke oven is uniformly fed onto the screen’s inlet section via a conveyor or chute.
2. Stratification & الانفصال: HighGforce vibration stratifies the material bed. Smaller particles pass through the precisely sized apertures of the screen deck(ق), while onsize overs continue across the deck surface.
3. تفريغ المنتج: Correctly sized unders material collects in a hopper below, while overs discharge at the screen’s end, ensuring clean separation into two or more product streams.

نطاق التطبيق: Primary sizing (سلخ فروة الرأس) and final grading of metallurgical coke, recrusher feed preparation, and dedusting operations in coke plants, مصانع الصلب, and carbon processing facilities.

القيود الرئيسية: Not designed for sticky materials without specialized deck technology; maximum feed size is constrained by screen design parameters; performance is contingent on correct installation and feed rate control.

3. الميزات الأساسية

Our Coke Vibration Screen design incorporates features targeting operational longevity and grading precision.

Modular Deck System | الأساس الفني: Independently tensioned, interchangeable panel frames | المنفعة التشغيلية: Allows for rapid replacement of individual worn sections without full deck downtime. Different panel types (ممحاة, البولي يوريثين, woven wire) can be mixed per deck for optimal life. | تأثير عائد الاستثمار: Reduces maintenance time by up to 60% per changeout event versus bolteddown systems.
DualMass Drive Technology | الأساس الفني: Two synchronized counterrotating masses generating a linear force | المنفعة التشغيلية: Delivers consistent stroke regardless of feed load fluctuations; requires lower motor horsepower; transmits minimal dynamic loads to the supporting structure. | تأثير عائد الاستثمار: يخفض استهلاك الطاقة بنسبة 1525% compared to bruteforce singlemass designs; reduces structural support costs.
Advanced Sealing & Dust Containment | الأساس الفني: Multistage labyrinth seals combined with positivepressure dust skirts | المنفعة التشغيلية: Contains fine coke dust at transfer points, protecting bearings and improving plant air quality. | تأثير عائد الاستثمار: يمتد عمر خدمة المحمل بأكثر من 30%, reducing a primary failure point and associated downtime costs.
AbrasionResistant Lining Package | الأساس الفني: Bolton wear plates (AR400/500) at all highimpact feed points and discharge lips | المنفعة التشغيلية: Protects the main screen body from abrasive wear, preserving structural integrity for decades. | تأثير عائد الاستثمار: Eliminates costly body repairs or premature fullunit replacement; defers major capital expenditure.
Tuned Isolation System | الأساس الفني: Computermodeled coil spring or rubber shear mount isolators matched to operating weight & frequency | المنفعة التشغيلية: يمتص أكثر 95% of dynamic vibration forces before they reach the support structure. | تأثير عائد الاستثمار: Prevents vibrationinduced fatigue cracking in plant infrastructure, avoiding significant civil repair costs.

4. المزايا التنافسية

| مقياس الأداء | Industry Standard Offerings | Our Coke Vibration Screen Solution | ميزة (% تحسين) |
| : | : | : | : |
| Screen Cloth Life (Primary Deck) | 24 Months (woven wire) | 69 Months (polyurethane/modular) | +125% average life extension |
| Bearing MTBF (متوسط ​​الوقت بين الفشل) | ~12,000 Operating Hours | ~18,000 Operating Hours | +50% improved reliability |
| Energy Consumption per Ton Screened| خط الأساس (100%)| Optimized Drive & Mass Design| 20% reduction typical |
| Maintenance Downtime per Year| 120180 ساعات (مُقدَّر)| 4070 ساعات (مُقدَّر)| ~65% reduction possible |

5. المواصفات الفنية

Specifications are tailored to client throughput requirements; standard models range from:

سعة / تصنيف: Designed for throughputs from 200 MTPH to over 1,500 MTPH of dry metallurgical coke (bulk density ~0.5 – 0.7 طن / م³).
متطلبات الطاقة: Drive motors from 7.5 كيلوواط ل 45 kW depending on size and Gforce requirement (عادة 46 G's), 400/690V AC, 3مرحلة.
مواصفات المواد: الإطار الرئيسي - الفولاذ الكربوني ST37/44; Wear liners – AR400/500 steel; Deck frames – hotdip galvanized steel; Screen surfaces – polyurethane panels or tensioned wire cloth as specified.
الأبعاد المادية: Widths from 1.2m to 3m; lengths from 4m to over 10m (single/triple deck). Total installed weight between ~5t – ~25t.
نطاق التشغيل البيئي: مصممة لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +50 درجة مئوية; suitable for outdoor installation with appropriate protection coatings.

6. سيناريوهات التطبيق

مصنع معالجة فحم الكوك مطحنة الصلب

تحدي: A major integrated steel mill experienced excessive fines generation (>8% 10مم) during final coke screening before blast furnace charging due to aggressive screen motion degrading fragile coke.
حل: Implementation of a customengineered Coke Vibration Screen with reduced throw angle polyurethane decks tuned for gentle stratification rather than aggressive throwing action.
نتائج: Fines generation reduced to below 5%, preserving premium lump coke yield valued at over $180k annually in recovered product revenue.

Independent Carbon Plant Recrusher Feed Prep

تحدي: Frequent blinding of screen decks by moist coke breeze was causing daily operational stoppages for manual rodding at an independent processor.
حل: Installation of our Coke Vibration Screen featuring nonblinding balltray decks combined with highGforce vibration to ensure continuous cleaning action.
نتائج: Eliminated daily cleaning downtime (~45 minutes/day), increasing annual available production time by over 250 hours while stabilizing feed consistency to downstream recrushers.

7 الاعتبارات التجارية

Our contract manufacturing model provides flexibility across project scales:

طبقات التسعير: Based on machine size/throughput capacity:
واجب قياسي (1200 MTPH): Customengineered units for greenfield sites or major expansions.

الميزات الاختيارية: Acoustic hoods/enclosures , spray mist systems , explosionproof motor/drive packages , advanced condition monitoring sensor ports , custom discharge hood configurations .

Service Packages are available separately:
1.Full OEM spare parts provisioning with guaranteed interchangeability .
2.Onsite commissioning supervision & operator training .
3.Preventive maintenance inspection contracts .
4.Fastresponse technical support .

Financing Options can be facilitated through thirdparty industrial equipment finance partners , offering leasetoown structures or term loans that align payments with your project's cash flow timeline .

التعليمات

Q1 Are your screens compatible with existing foundations?
A1 Our engineering team provides full foundation load drawings . The tuned isolation system minimizes dynamic loads , often allowing our screens to replace older units on existing foundations after a professional structural review .

Q2 What is the expected impact on my overall plant noise levels?
A2 Field data shows sound pressure levels typically measure between7582 dB(أ) at one meter when properly installed . Optional acoustic enclosures can reduce this further if required .

Q3 How do you ensure consistent product quality across manufactured units?
A3 As a contract manufacturer we operate under strict ISOcertified quality management systems . Every Coke Vibration Screen undergoes runin testing prior to shipment , with certified dimensional reports provided .

Q4 What are typical lead times?
A4 Lead times vary by complexity . Standard heavyduty models typically have a lead time of1418 weeks from order approval . Expedited manufacturing slots may be available .

Q5 Can you supply matching conveyors chutes transfer towers ?
A5 Our core expertise is in vibrating screens . We provide detailed interface drawings but recommend working with your preferred bulk handling contractor or we can introduce qualified partners .

Q6 What warranty terms apply?
A6 We provide a standard24month warranty on structural components against defects in materials workmanship Bearings drives motors carry their manufacturers' warranties typically12 months

Q7 Do you offer performance guarantees?
A7 We guarantee mechanical performance build quality throughput capacity based on agreedupon material characteristics Guarantees regarding fines reduction are projectspecific based on pilot test data