1. فتحة مدفوعة بنقطة الألم

Is your coke handling operation losing profitability to inefficient screening? Common challenges with conventional screens directly impact your bottom line. هل تعاني:
Excessive Product Loss: Fines and valuable coke breeze passing through worn or inefficient screen decks, تمثل خسارة الإيرادات المباشرة مع كل طن تتم معالجته.
ارتفاع فترات توقف الصيانة: Frequent failures of screen decks, محامل, or exciters due to the extreme abrasion and impact of coke, leading to unscheduled stoppages and production delays.
المسببة للعمى & Poor Efficiency: Moisture or sticky fines blinding screen meshes, drastically reducing effective screening area and throughput, forcing recirculation and increasing energy costs.
تصنيف المنتج غير متناسق: Unreliable particle size separation resulting in offspec product for blast furnace or foundry customers, risking contract penalties and reputational damage.
مخاوف تتعلق بالنزاهة الهيكلية: Constant, highimpact vibration leading to fatigue cracks in the screen body or support structure, creating major safety risks and costly capital repairs.

السؤال الأساسي لمديري المصانع هو: كيف يمكنك تحقيق الدقة, reliable coke classification while maximizing uptime and protecting your material yield?

2. نظرة عامة على المنتج

The Export Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the dry classification of metallurgical coke and coke breeze. Designed for robustness in harsh environments, it separates crushed coke into precise size fractions critical for blast furnace efficiency and other industrial processes.

سير العمل التشغيلي:
1. مقدمة الأعلاف: Sized coke from crushers is evenly distributed onto the feed box of the vibrating screen.
2. التقسيم الطبقي & الانفصال: كثافة عالية, linear or circular vibration stratifies the material bed. Smaller particles descend to contact the screen cloth apertures, while larger particles travel across the deck surface.
3. حجم الكسر التفريغ: Correctly sized particles pass through the screen mesh (أقل من الحجم), while oversized particles discharge at the deck end (كبيرة الحجم). Multideck configurations allow for simultaneous separation into several product grades.

نطاق التطبيق: Primary and secondary screening of metallurgical coke, coke breeze recovery, sizing for sinter plants, and prescreening for gasification processes.

القيود: غير مصمم لتطبيقات الفحص الرطب أو للمواد ذات الخصائص اللاصقة الشديدة دون معالجات سطح السفينة المتخصصة.

3. الميزات الأساسية

نظام سطح السفينة وحدات | الأساس الفني: الكرات, subframe mounted polyurethane or rubber clad steel panels | المنفعة التشغيلية: Dramatically reduced replacement time; individual panels can be changed without full deck dismantling. | تأثير عائد الاستثمار: يخفض وقت التوقف عن الصيانة المخطط له بنسبة تصل إلى 60%, زيادة ساعات التشغيل السنوية.

HeavyDuty Exciter Assembly | الأساس الفني: Internally mounted, greaselubricated vibrator unit with oversized bearings and labyrinth seals | المنفعة التشغيلية: Isolated from direct material impact; delivers consistent amplitude under variable load conditions. | تأثير عائد الاستثمار: Proven service intervals exceeding 8,000 ساعات تحت التشغيل المستمر, reducing spare part consumption.

البناء هوكبولتيد | الأساس الفني: Highshear strength fastener system used throughout the main frame and side plates | المنفعة التشغيلية: Eliminates weld fatigue failures; creates a rigid, maintenancefree body structure resistant to crack propagation. | تأثير عائد الاستثمار: يمتد عمر الخدمة الهيكلية لسنوات, تجنب تكاليف استبدال رأس المال المبكرة.

Tiered Dust Enclosure | الأساس الفني: Multisegment rubber skirtboard system with quickrelease clamps at multiple transfer points | المنفعة التشغيلية: Contains dust emission at feed, تسريح, and side skirts; improves plant environmental compliance. | تأثير عائد الاستثمار: Mitigates material loss as airborne fines and reduces housekeeping labor requirements.

نظام تعليق زنبركي مضبوط | الأساس الفني: Computermodeled coil spring or rubber buffer system matched to dynamic load parameters | المنفعة التشغيلية: عزلات تصل إلى 85% القوى الديناميكية من الهيكل الداعم; allows installation on elevated platforms. | تأثير عائد الاستثمار: Eliminates costly structural reinforcement needs during installation and minimizes vibration transmission.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (الشاشات التقليدية) | Export Coke Vibration Screen Solution | ميزة (% تحسين) |
| : | : | : | : |
| عمر لوحة سطح السفينة| 36 months with steel wire mesh | 1218 months with polyurethane clad panels | +150% متوسط ​​التحسن |
| التوفر السنوي| ~8590% (بما في ذلك التوقفات المخطط لها)| >94% (بيانات ميدانية موثقة) |>4 percentage point gain |
| كفاءة الفحص| 8590% on dry 6mm separation| باستمرار >94% on same duty| +5% reduction in misplaced fines |
| استهلاك الطاقة لكل طن| خط الأساس (100%)| محرك الأمثل & توازن الكتلة يقلل السحب بنسبة ~15%| 15% lower operational cost |
| تثبيت & وقت التشغيل| 57 days for full assembly on site| Preassembled modules reduce field work to 23 أيام|<50% of standard time |

5. المواصفات الفنية

سعة / تصنيف: تعتمد على النموذج; تتراوح من 500 MTPH إلى 2,500 MTPH من فحم الكوك الجاف (bulk density ~0.50.6 t/m³).
متطلبات الطاقة: قيادة المحركات من 15 كيلوواط ل 45 كيلوواط لكل وحدة هزاز (عادة محرك مزدوج), 400/690الخامس و, IP66 protection standard.
مواصفات المواد:
إطارات سطح السفينة & لوحات جانبية: فولاذ مقاوم للتآكل (AR400/450).
الطوابق الشاشة: Modular polyurethane panels with embedded steel reinforcement; optional rubberclad steel or tensioned wire cloth.
الإطار الرئيسي & الأعضاء المتقاطعة: Heavywalled structural steel with corrosioninhibiting primer.
الأبعاد المادية: Singledeck widths from 1.8m to 3.6m; أطوال من 4.8 م إلى 7.2 م.
نطاق التشغيل البيئي: درجة الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية; designed for outdoor installation with appropriate electrical components.

6. سيناريوهات التطبيق

Integrated Steel Plant Blast Furnace Feed

Challenge A major steel producer faced consistent fines (5مم) contamination in their BFgrade coke (2575مم), affecting furnace permeability and increasing coke rate.
Solution Installation of a primary Export Coke Vibration Screen with two decks following secondary crushing.
Results Achieved a clean +25mm product with less than 3% undersize contamination while recovering 5mm breeze for sinter plant use—a quantifiable reduction of $12/ton in effective BF feed cost.

تاجر فحم الكوك المنتج

Challenge Offspec product batches due to inconsistent screening after rain events caused moistureinduced blinding on traditional screens.
Solution Implementation of our screens equipped with specialized antiblinding polyurethane decks featuring slotted apertures and balltray cleaning systems.
Results Screening efficiency remained above 92% even with surface moisture up to 7%, eliminating penalty clauses related to product sizing in supply contracts within one quarter.

7 الاعتبارات التجارية

Export Coke Vibration Screens are offered in three primary tiers:

1. سلسلة الواجب القياسية: لقدرات تصل إلى ~ 800 ميل بالساعة. Includes core heavyduty construction features ideal for most merchant coke operations.
2. سلسلة الثقيلة: For capacities from ~800 MTPH to ~1,800 MTPH featuring enhanced exciter specifications and premiumtier bearing assemblies—the recommended choice for integrated steel plants.
3. Extra Heavy Duty Series: For ultrahighcapacity applications exceeding ~1，800 MTPH， incorporating duplex bearing exciters， تصميم الإطار المقوى，and premium dust sealing packages．

Optional features include stainless steel fasteners，full stainless steel skirting，integrated spray systems for limited dust suppression，and condition monitoring sensor ports．

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including scheduled inspections，تحليل الاهتزاز，and guaranteed spare parts availability．Financing options including equipment leasing are available through accredited partners．

التعليمات

Q What is the lead time for a typical Export Coke Vibration Screen?
A Lead times vary by model complexity．For standard configurations，expect delivery within X weeks upon order confirmation．Customized solutions may require additional engineering time．

Q Can this equipment integrate into our existing PLCcontrolled plant？
A Yes．All drives are compatible with standard industrial motor starters．The screen itself is supplied readyforsignal connection；it does not include complex control logic but can interface with your plant’s start/stop interlocks．

Q How does this design handle variations in feed rate？
A The exciter system generates a constant force independent of load．While efficiency is optimized at design capacity，field data shows performance degradation remains minimal (±2%) within a ±20% feed rate fluctuation．

Q What are the primary wear items？
A The primary consumables are the modular deck panels followed by wear liners on feed boxes．Spare parts kits based on recommended annual usage are available．

Q Do you provide installation supervision？
A Yes．Professional commissioning supervision is offered as an optional service package．This includes final alignment checks，initial startup assistance，and operator training．

Q Are your technical specifications guaranteed？
A All performance figures stated are based on standard test conditions using defined material characteristics．We provide written performance guarantees as part of our commercial proposal based on your specific application data sheet．

Q What financing structures do you offer？
A We work with thirdparty financial institutions that offer operating leases，capital leases/finance leases,and traditional purchase loans.Structures can be tailored over terms typically ranging from X years