1. فتحة مدفوعة بنقطة الألم

Is your coke processing operation struggling with inefficient screening that impacts final product quality and plant throughput? Common challenges with conventional vibration screens in this harsh application include:

Premature Screen Cloth Failure: Abrasive coke breeze and thermal cycling cause rapid wear, مما يؤدي إلى كثرة, costly shutdowns for media replacement and unplanned downtime.
فصل الغرامات غير فعال: Inconsistent vibration or screen blinding results in undersize material contaminating the product stream or valuable fines being lost to waste, directly affecting yield and revenue.
Excessive Structural Fatigue: The combined load of abrasive coke and constant vibratory forces can lead to weld cracks, فشل اللوحة الجانبية, and catastrophic structural damage, requiring major rebuilds.
عبء الصيانة العالي: محامل, المحركات, and springs under constant stress from heavy loads demand excessive lubrication, تقتيش, and replacement, رفع التكاليف التشغيلية.

Are you seeking a screening solution that delivers consistent grade control, maximizes uptime in a 24/7 environment, and reduces your total cost of ownership?

2. نظرة عامة على المنتج

لدينا هندسيا Coke Vibration Screen Processing Plant is a heavyduty linear motion screening system designed for the precise sizing and scalping of metallurgical coke and coke breeze in processing circuits. It is built to handle hightonnage, abrasive materials while operating reliably in demanding plant conditions.

سير العمل التشغيلي:
1. يٌطعم & توزيع: Sized coke from crushers or ovens is evenly distributed across the full width of the screen’s robust feed box.
2. التقسيم الطبقي الدقيق & الانفصال: Dual vibratory motors generate a linear motion that stratifies material, forcing fines through the specified aperture of the durable screen cloth while conveying oversize material to discharge.
3. التفريغ الفعال: Separated fractions—oversize product (على سبيل المثال, +25mm blast furnace coke) and undersize fines (نسيم فحم الكوك)—are discharged into distinct chutes for downstream processing or stockpiling.

نطاق التطبيق: التحجيم الأولي لفحم الكوك المعدني, scalping of oven charge materials, dedusting of coke breeze, and final product separation in coke handling plants.

القيود: This equipment is engineered for dry screening applications. Performance in wet screening circuits or with highly sticky materials may require specific configuration adjustments.

3. الميزات الأساسية

HeavyDuty Deck Assembly | الأساس الفني: وحدات, boltin tensioning system with reinforced crossmembers | المنفعة التشغيلية: تمكن سريع, individual panel changes without full deck disassembly, minimizing downtime for cloth replacement. | تأثير عائد الاستثمار: يقلل وقت تغيير وسائط الشاشة بما يصل إلى 40%, زيادة توافر النباتات.

Controlled Vibration Mechanism | الأساس الفني: Synchronized dual outofbalance motors generating a linear throw; force can be adjusted via external counterweights. | المنفعة التشغيلية: Operators can finetune amplitude for optimal material travel rate and separation efficiency for varying feed conditions. | تأثير عائد الاستثمار: يحسن كفاءة الفحص عن طريق 515%, reducing recirculating load and improving product grade consistency.

نظام بطانة مقاوم للتآكل | الأساس الفني: ألواح بولتون المقاومة للتآكل مصنوعة من الفولاذ AR400 في جميع نقاط التأثير الحرجة (صندوق تغذية, تفريغ الشفاه). | المنفعة التشغيلية: Protects the main frame structure from wear, extending the equipment’s structural service life by several years. | تأثير عائد الاستثمار: Eliminates need for frequent weld repair on the frame body, cutting longterm maintenance capital expenditure.

محركات هزازة مغلفة بالغبار | الأساس الفني: حماية حاصلة على تصنيف IP66 مع أختام متاهة على أعمدة القيادة. | المنفعة التشغيلية: Prevents ingress of abrasive coke dust into motor bearings, the leading cause of vibrator unit failure. | تأثير عائد الاستثمار: يمتد عمر خدمة المحمل بأكثر من 50%, reducing spare parts costs and failurerelated stoppages.

HuckBolted Frame Construction | الأساس الفني: Highshear strength fasteners used throughout the main side plate and crossmember joints. | المنفعة التشغيلية: Creates a rigid frame resistant to fatigue cracking under dynamic loads compared to traditional welded designs. | تأثير عائد الاستثمار: Dramatically reduces risk of unexpected structural failure, ensuring multiyear operational integrity with minimal inspection overhead.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة | لدينا حل شاشة اهتزاز فحم الكوك | ميزة (% تحسين) |
| : | : | : | : |
| حياة قماش الشاشة (سطح السفينة الأساسي) | 68 weeks under standard abrasion | 1014 weeks with recommended media | +4075% عمر خدمة أطول |
| Annual Bearing MTBF (Vibrator Units) | ~ 8,000 ساعة | 12,000+ hours demonstrated in field data| +50% تحسين |
| Structural Integrity Period (لإصلاح اللحام الرئيسي الأول) | 1824 شهور| 36+ months documented in similar installations| +100% تحسين |
| كفاءة الفحص (for 5mm separation)| ~85% consistent efficiency| 9295% achievable with optimized throw/angle| +812% increase in yield accuracy|
متوسط ​​الوقت بين حالات الفشل

5. المواصفات الفنية

نطاق النموذج & سعة: Sizes from 1.2m x 3m to 2.4m x 6m; throughput capacity from 150 لأكثر من 1000 metric tons per hour depending on aperture size and feed gradation.
وحدة القيادة: Dual externallymounted vibratory motors; total power range from 15 كيلوواط ل 45 kW per motor pair.
بناء سطح السفينة: Multislope capable; up to three decks standard. Features reinforced crossmembers with rubber buffer coating to protect screen cloth.
إطار & Body Material: Main side plates constructed from highyield strength steel (Q345B minimum). Critical wear areas lined with replaceable AR400 steel liners.
الأبعاد المادية & وزن: يختلف بشكل كبير حسب النموذج; largest model (~2.4m x 6m) تقريبا. weight of 1214 tonnes excluding support structure.
نطاق التشغيل البيئي: مصمم لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية. معيار الحماية من الغبار; optional weather covers available for outdoor installation.

6. سيناريوهات التطبيق

Integrated Steel Plant Coke Handling Facility

تحدي: A major steel producer faced excessive downtime every 67 weeks for screen cloth changes on their primary coke screens due to abrasion wear from blast furnacegrade coke (+25مم). Unplanned stoppages were disrupting steady feedstock supply to the furnaces.
حل: Implementation of our heavyduty Coke Vibration Screen featuring a quickchange deck system and ARlined feed zone.
نتائج: Screen media changeout intervals extended to an average of 11 weeks per setup time reduced by onethird due to modular design). This contributed to an estimated increase in annual plant availability by over 120 ساعات.

Merchant Coke Producer – Breeze Recovery Circuit

تحدي: Significant volumes of valuable sub10mm coke fines (“breeze”) were being lost as waste due to inefficient separation on aging screens suffering from frequent blinding.
حل: Installation of a twodeck linear motion screen configured specifically for dedusting at high capacity using nonblinding polyurethane screen panels on the lower deck.
نتائج: Screening efficiency for 5mm material improved from an estimated ~82% to consistently measured levels above >93%. This allowed recovery of an additional ~18 tonnes per day of saleable breeze product directly impacting revenue.

7 الاعتبارات التجارية

Our Coke Vibration Screens are offered as engineeredtoorder solutions based on your specific capacity requirements:

الطبقة القياسية (شارع): Includes core heavyduty frame design base vibrator units dust encapsulation basic liners Designed as reliable replacements for existing units
مستوى الأداء (حزب العمال):(Most common choice) Includes all ST features plus enhanced quickchange deck system adjustable counterweight vibrators upgraded AR400 liners at all wear points rubber buffer coated crossmembers
الطبقة المميزة (PMT):(For maximum uptime operations) Includes all PT features plus condition monitoring sensor ports premium SKF/FAG class bearings optional automated lubrication system preinstalled

Optional features include custom chutework weather covers explosionproof motor ratings different types

Service packages range from basic commissioning supervision comprehensive multiyear maintenance agreements including scheduled inspections parts kits priority support

Financing options including equipment leasing are available through our partners allowing you preserve capital expenditure budgets

التعليمات

What tonnage range can your Coke Vibration Screens handle?
Our models are scalable designed handle capacities ranging between metric tons hour depending size number decks required aperture We will specify correct model based detailed analysis feed material specifications

How does this screen handle thermal expansion hot feed material?
Design incorporates allowances thermal expansion key areas such between deck frames main side plates Use hightemperature grease bearings standard Allowing handle typical temperatures associated cooled metallurgical without compromising integrity

What type screen media do you recommend?
We provide technical support select optimal media based application For primary sizing coarse coke recommend rugged punched plate secondary sizing fine separation recommend tensioned polyurethane or woven wire panels offer best balance life resistance blinding

Can integrate existing plant PLC control systems?
Yes The vibratory motor starters can be interfaced plant control systems provide standard running fault feedback signals Optional variable frequency drives be supplied allow remote adjustment vibration intensity match realtime conditions

What typical delivery lead time engineered unit?
For standard configurations lead time typically weeks receipt order Customized designs may require additional engineering time We maintain critical spare parts inventory ensure support after installation