1. فتحة مدفوعة بنقطة الألم

Is your coke screening operation plagued by persistent, costly inefficiencies? لمديري المصانع والمقاولين الهندسيين, the challenges of screening bulk metallurgical coke directly impact throughput, جودة المنتج, and bottomline profitability. وتشمل العقبات التشغيلية المشتركة:

المسببة للعمى & تحمل أكثر: Fine coke breeze and moisture cause screen mesh blinding, تقليل منطقة الفحص الفعالة. معًا, undersize material carries over with the product stream, contaminating blast furnace feed and degrading its performance.
التوقف المفرط للصيانة: The abrasive nature of coke accelerates wear on screen decks, لوحات جانبية, and exciters. Frequent component replacement leads to unplanned downtime and high spare parts inventories.
فصل الغرامات غير فعال: Inadequate separation of the 010mm fraction results in lost revenue from breeze sales and inefficient recycling within the coke plant.
التعب الهيكلي & Failure: High Gforces from traditional vibrators transfer damaging stress to the screen body and support structure, leading to weld cracks and catastrophic frame failures.
استهلاك عالي للطاقة: Inefficient drive systems and oversized motors run continuously, contributing to significant, nonproductive power costs.

Are you seeking a solution that reduces downtime by 30% or more while ensuring consistent product sizing? The answer lies in selecting a coke vibration screen engineered specifically to overcome these materialspecific challenges.

2. نظرة عامة على المنتج

The equipment in focus is a heavyduty Coke Classification Vibrating Screen, designed for highcapacity sizing of hot or cold metallurgical coke (25mm 80mm) from oven discharge and the subsequent separation of coke breeze (0mm 10mm).

سير العمل التشغيلي:
1. يٌطعم & توزيع: Bulk coke is uniformly fed onto the robust feed box, which distributes the material across the full width of the primary screen deck.
2. التحجيم الأساسي: A highstrength wire mesh or punch plate deck performs the primary separation, allowing undersize material (breeze and small fractions) to pass through.
3. الفحص الثانوي & إزالة الغرامات: A second deck further refines the separation, ensuring maximum recovery of marketable coke breeze.
4. تسريح: Correctly sized foundry or blast furnace coke discharges from the screen end, while separated fines are collected via a dedicated chute for processing or sale.

نطاق التطبيق & القيود:
This equipment is designed for dry or slightly moist coke screening in fixed plant installations. It is not suitable as a replacement for rotary breakers or for handling highly sticky materials without pretreatment. Maximum lump size should not exceed 150% of the nominal top deck aperture.

3. الميزات الأساسية

نظام سطح السفينة وحدات | الأساس الفني: الكرات, pretensioned panel design with polyurethane side tensioning strips | المنفعة التشغيلية: Individual deck sections can be replaced in under 2 hours without welding or specialized tools, minimizing downtime for maintenance. | تأثير عائد الاستثمار: Reduces screen cloth changeout time by up to 60%, زيادة توافر النباتات بشكل مباشر.

تقنية محرك DualMass | الأساس الفني: Two synchronized counterrotating masses generating a linear stroke | المنفعة التشغيلية: Transfers dynamic forces into the screening motion rather than the support structure; allows for lower horsepower motors due to efficient energy transfer. | تأثير عائد الاستثمار: Cuts structural maintenance costs by an estimated 40% and reduces operational energy consumption by 1525%.

حزمة بطانة مقاومة للتآكل | الأساس الفني: Bolton wear plates made from AR400 steel at all critical impact points (صندوق تغذية, تفريغ الشفاه) | المنفعة التشغيلية: Protects the main screen frame from wear, extending its service life beyond 10 years under typical conditions. | تأثير عائد الاستثمار: Eliminates need for frequent frame repair or replacement, providing a predictable longterm asset cost.

Environmental Sealing System | الأساس الفني: Multistage labyrinth seals combined with durable rubber dust curtains at transfer points | المنفعة التشغيلية: Contains dust emissions at source, improving site environmental compliance and operator health conditions. | تأثير عائد الاستثمار: Lowers costs associated with airborne particulate control and reduces housekeeping labor.

Tuned Spring Isolation | الأساس الفني: Computermodeled coil spring or rubber shear mount system matched to screen weight and operating frequency | المنفعة التشغيلية: عزلات تصل إلى 95% of dynamic vibration from the supporting structure, preventing damage to building foundations and adjacent equipment. | تأثير عائد الاستثمار: Eliminates secondary structural costs and prevents costly vibrationinduced failures in plant infrastructure.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة | حل شاشة اهتزاز فحم الكوك | ميزة (% تحسين) |
| : | : | : | : |
| وقت استبدال لوحة السطح| 68 ساعات (welded) | <2 ساعات (bolted modular) | ~70% أسرع |
| حياة التعب الهيكلي| 35 years before major repair| 8+ years with protected frame| >100% يزيد |
| كفاءة الفحص (Breeze Removal)| ~85% efficiency| باستمرار >92% كفاءة| ~8% more product recovery |
| Operating Noise Level| 95105 ديسيبل(أ) و 1 م| <85 ديسيبل(أ) و 1 م| ~15 dB reduction |
| Annual Power Consumption| خط الأساس (100%) for same duty| Reduced motor size + محرك فعال| 1525% تخفيض |

5. المواصفات الفنية

تصنيف القدرات: تعتمد على النموذج; النطاق القياسي من 300 MTPH إلى 1,200 MTPH of bulk coke (bulk density ~0.5 t/m³).
متطلبات الطاقة: Driven by dual lowvoltage AC motors (على سبيل المثال, 2 س 11 كيلوواط ل 2 س 30 كيلوواط), depending on model size and stroke configuration.
مواصفات المواد:
إطار: فولاذ كربوني شديد التحمل (S355JR), تخفيف التوتر.
الطوابق: Options include highcarbon steel wire mesh (65من), HARDOX® punch plates, or polyurethane panels.
حماية التآكل: AR400 steel liners standard at all impact zones.
الأبعاد المادية: Typical singledeck unit footprint ranges from (ل)6m x (دبليو)2.5m x (ح)1.8m to (ل)9m x (دبليو)3.5m x (ح)2م.
نطاق التشغيل البيئي: مصممة لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +50 درجة مئوية; capable of handling hot coke up to ~200°C with appropriate deck material selection.

6. سيناريوهات التطبيق

Integrated Steel Plant Coke Oven Battery Discharge

تحدي: A major steel producer faced severe blinding on their existing screens due to residual moisture in quenched coke. This caused frequent overloads on downstream crushers and inconsistent blast furnace feed sizing (+/15mm variance).
حل: Implementation of two parallel heavyduty linear motion Coke Vibration Screens featuring nonblinding balltray decks on the fines removal section.
نتائج: Screening efficiency stabilized at ≥94%. Oversize contamination was eliminated (<1%), protecting crusher integrity. The consistent product sizing contributed to a documented ~3% improvement in blast furnace burden permeability.

Merchant Coke Producer – Breeze Recovery

تحدي: A merchant plant was losing significant revenue due to poor fines capture; an estimated 810% of saleable breeze was being incorrectly routed back into crusher feed circuits as "circulating load."
حل: Retrofitting a dedicated Coke Vibration Screen with a finemesh secondary deck into their product classification circuit postcrushing.
نتائج: Breeze recovery increased from ~82% to over 95%, creating an additional revenue stream exceeding project payback within one year based on market prices for fuelgrade fines.

7.الاعتبارات التجارية

يتم تقديم شاشات اهتزاز فحم الكوك لدينا عبر ثلاثة مستويات أساسية:
سلسلة الواجب القياسية: For capacities up to ~500 MTPH with robust base specifications; مثالية للمحطات الصغيرة أو دورات العمل الأقل شدة.
سلسلة الثقيلة (>500 MTPH): Our most common specification featuring all core technologies listed above; designed for continuous operation in integrated steel plants.
حلول هندسية مخصصة: For unique layouts requiring multiple discharge points specific grades like nut coke separation

تشمل الميزات الاختيارية:
Enclosed designs with integrated dust extraction flanges
Stainless steel components for highly corrosive environments
أجهزة استشعار متقدمة لمراقبة الحالة
محركات التردد المتغير

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including guaranteed spare parts availability Financing options including leasing are available through our partners

التعليمات

What is your typical lead time?

For standard HeavyDuty Series models lead time is typically between weeks depending on current production schedules Custom engineered solutions require additional engineering time

Are your screens compatible with our existing chutes?

Our engineering team will review your existing layout drawings We provide detailed interface specifications including loads connection points ensuring seamless integration into your current transfer system

How do you guarantee performance?

Performance guarantees are based on agreedupon feed material characteristics We provide certified capacity curves based on laboratory testing data Guarantees typically cover throughput capacity under specified conditions

What does commissioning involve?

Our standard package includes supervision installation mechanical alignment initial startup process tuning We ensure correct operation before handover Documentation includes detailed manuals training materials

What are payment terms?

Standard commercial terms involve progress payments tied key milestones Typically % upon order % before shipment balance upon completion satisfactory commissioning Letters credit accepted Financing options available upon request