H1: HighCapacity Custom Coke Vibration Screens for Precision Sizing and Scalping

1. فتحة مدفوعة بنقطة الألم

Managing coke feedstock quality presents persistent challenges that directly impact downstream process efficiency and plant profitability. هل تتنافس مع:
Sizing Inconsistencies: Variable feed leading to offspec product, causing rejections or penalties from blast furnace operators.
توليد الغرامات المفرطة: Conventional screening methods contributing to excessive breakage of highvalue lump coke, eroding yield and revenue.
التوقف غير المخطط له: Frequent screen cloth changes and structural fatigue from abrasive coke abrasion, resulting in costly production halts.
Scalping Inefficiencies: Inadequate removal of oven debris (silicon carbide, "oven stone") and oversized material, risking damage to crushers and conveyors.
عبء الصيانة العالي: محامل, الينابيع, and decks failing prematurely under heavy loads, driving up spare parts costs and labor hours.

If these operational costs are affecting your bottom line, the specification of your screening equipment is a critical leverage point. هدف مصمم Custom Coke Vibration Screen is not merely a commodity filter; it is a core component for achieving grade control, protecting capital equipment, and maximizing throughput.

2. نظرة عامة على المنتج

أ Custom Coke Vibration Screen is a heavyduty vibratory screening machine specifically engineered for the dry separation and classification of metallurgical coke. تصميمه يعطي الأولوية للمتانة, accurate particle separation, and highvolume handling in harsh environments.

سير العمل التشغيلي:
1. مقدمة الأعلاف: Raw coke from the quench car or storage is conveyed onto the screen's robust feed box.
2. التقسيم الطبقي & الانفصال: A highenergy, linear or elliptical vibratory motion stratifies the material bed. Smaller particles pass through precisely sized screen deck apertures.
3. تفريغ الكسر: Correctly sized lump coke discharges from the deck end as product. Undersize (نسيم فحم الكوك) passes through to a separate collection chute. Oversize material or scalped debris exits via a dedicated reject spout.

نطاق التطبيق & القيود:
نِطَاق: Primary sizing of hot or quenched metallurgical coke, scalp removal of oven debris (SiC), إزالة الغبار (إزالة نسيم), and routing of multiple product fractions. Suitable for sinter plant feed preparation.
القيود: Not designed for wet screening applications or for materials with high moisture content that causes blinding. Maximum capacity is defined by physical aperture size and material bulk density.

3. الميزات الأساسية

نظام سطح السفينة وحدات | الأساس الفني: Independently tensioned panel frames | المنفعة التشغيلية: Allows for rapid replacement of individual screen sections without full deck shutdown | تأثير عائد الاستثمار: يقلل من وقت توقف الصيانة بنسبة تصل إلى 60% per changeout

حزمة بطانة مقاومة للتآكل | الأساس الفني: Bolton AR steel plates in highwear zones (صندوق تغذية, تفريغ الشفاه) | المنفعة التشغيلية: يحمي الفولاذ الهيكلي من التآكل, extending mainframe service life by multiples | تأثير عائد الاستثمار: Eliminates costly structural repair campaigns; defers capital replacement

عزل زنبركي ملفوف للخدمة الشاقة | الأساس الفني: Progressiverate steel coil springs | المنفعة التشغيلية: Absorbs dynamic loads while transmitting minimal vibration to the support structure | تأثير عائد الاستثمار: Reduces foundational stress cracks and associated civil maintenance costs

Centralized Greasing Lube System | الأساس الفني: Manifold with lines to all bearing points | المنفعة التشغيلية: Ensures consistent lubrication of vibrator shaft bearings under high thermal stress | تأثير عائد الاستثمار: يمتد عمر خدمة التحمل; prevents catastrophic failure causing extended unplanned downtime

Variable Amplitude & Frequency Drive | الأساس الفني: Adjustable eccentric weights & VFD motor control | المنفعة التشغيلية: Operators can tune screen motion for optimal stratification with varying feed rates or coke characteristics | تأثير عائد الاستثمار: Maintains screening efficiency across shifts, maximizing consistent product yield

4. المزايا التنافسية

| مقياس الأداء | الحل القياسي للصناعة | حل شاشة اهتزاز فحم الكوك المخصص | ميزة (% تحسين) |
| : | : | : | : |
| حياة قماش الشاشة (Lump Deck) | Standard woven wire mesh | Reinforced polyurethane panels with steel backing grid | +150200% عمر |
| تحمل MTBF (متوسط ​​الوقت بين الفشل) | ~8,000 hours in harsh service | >12,000 hours with specialized sealing & أنظمة التشحيم| +50% operational reliability |
| Screening Efficiency at 80mm cut point| ~8590% efficiency| باستمرار >94% efficiency via optimized throw & زاوية| +59% more product on spec |
| StructureBorne Vibrations Transmitted to Support| Significant harmonic vibration observed| Isolated via tuned spring system & subframe design| الحد من >70% measured vibration |
| التكلفة الإجمالية للملكية (5فترة سنة)| High consumable & repair costs| Predictable maintenance schedule with protected structure| موثقة 2535% انخفاض التكلفة الإجمالية للملكية |

5. المواصفات الفنية

تصنيف القدرات: نماذج من 500 الهيدروكربونات النفطية إلى 2,500+ TPH capacity for metallurgical coke (الكثافة الظاهرية ~0.5–0.7 طن/م3).
متطلبات الطاقة: Driven by 15 كيلوواط ل 45 kW vibrator motors (depending on size), standard 400/690V AC supply.
مواصفات المواد: Mainframe constructed from heavyduty S355JR steel; critical wear areas lined with Hardox 400/500 أو ما يعادلها من لوحة AR; corrosionresistant paint system.
الأبعاد المادية: Single or doubledeck configurations; typical deck widths from 1.8m to 3.6m; أطوال من 4.8 م إلى 7.2 م.
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 heatresistant components.

6. سيناريوهات التطبيق

Integrated Steel Plant Blast Furnace Feedstock Preparation

تحدي: A major mill faced inconsistent blast furnace performance linked to variable coke size distribution and periodic contamination from oven debris.
حل: Installation of a primary scalping Custom Coke Vibration Screen with a coarse top deck for debris removal and a lower sizing deck.
نتائج: Achieved consistent lump coke sizing (>80مم) مع <2% oversize/undersize variability; eliminated downstream crusher damage events; سجلت أ 1.5% reduction in blast furnace coke rate within one quarter.

Merchant Coke Producer Yield Optimization

تحدي: The client's existing screens generated excessive fines (10mm breeze), converting highvalue lump product into lowerrevenue streams.
حل: Implementation of a twindrive Custom Coke Vibration Screen featuring polyurethane decks designed for reduced abrasioninduced breakage.
نتائج: Fines generation reduced by an average of 18%; lump coke yield increased correspondingly, directly boosting annual revenue by an estimated $1.2M at prevailing market prices.

7 الاعتبارات التجارية

Equipment pricing tiers are determined by size/capacity (deck surface area), مواصفات المواد (standard vs premium AR linings), drive configuration (single vs dual), and control sophistication (basic vs PLCintegrated).

الميزات الاختيارية:
Dust encapsulation hoods
Aircooled vibrator units
أجهزة استشعار متقدمة لمراقبة الحالة (الاهتزاز/درجة الحرارة)
مكونات من الفولاذ المقاوم للصدأ للبيئات شديدة التآكل

تتضمن حزم الخدمة عادة:
Extended warranty plans covering bearings and structural integrity
التفتيش السنوي & vibration analysis programs
Onsite training for operation & الصيانة الوقائية

Financing options available include capital purchase through project finance partners or longterm operating lease agreements designed to preserve capital budgets.

8 التعليمات

Q1 Are your screens compatible with existing conveyor layouts?
A1 Our engineering team designs custom feed boxes discharge heights based on your specific layout drawings ensuring seamless integration into your current transfer points

السؤال الثاني: ما هو التأثير المتوقع على مستويات الضوضاء الإجمالية في المصنع؟?
A2 Field data shows our fully isolated designs typically operate below dB(أ) levels specified by most industrial health standards reducing noise pollution concerns

Q3 How does this solution address screen blinding issues common with sticky materials?
A3 While primarily dry screens we offer optional deck heating systems ball tray decks antiblinding devices tailored if minor moisture is present

س 4 ما هي المهل الزمنية النموذجية?
A4 Lead times vary based on complexity Standard configurations require weeks while fully customized units require weeks following finalized engineering approval

س 5 هل يمكنك تقديم ضمانات الأداء?
A5 Yes we provide contractual guarantees on throughput capacity screening efficiency based on agreedupon feed material analysis

Q6 What spare parts inventory do you recommend?
A6 We provide a critical spares kit recommendation list including tensioning hardware specialized gaskets drive belts ensuring minimal waiting time for common wear items