1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Is your coke handling operation plagued by inconsistent product quality, generación excesiva de multas, y paradas de mantenimiento no planificadas? Para gerentes de planta que supervisan el cribado de coque, common challenges directly impact profitability and throughput:
Contaminación del producto & Rejections: Inefficient separation allows undersize fines to contaminate blast furnace feedstock or anodegrade product, leading to customer penalties and degraded metallurgical performance.
Premature Screen Deck Failure: The extreme abrasiveness of hot or cold coke accelerates wear on screen panels and support structures, causing frequent, costly replacements and production stoppages.
Cegador & Continuar: Sticky coke particles and moisture can blind screen apertures, while insufficient vibration leads to material carryover, drastically reducing effective screening capacity and classification accuracy.
Fatiga estructural & Transmisión de vibración: Poorly engineered vibratory motion transmits damaging harmonics to the base frame and surrounding infrastructure, risking longterm structural integrity.

Are you seeking a screening solution engineered not just to move material, but to precisely classify it while withstanding the punishing environment of coke handling? The right bespoke vibration screen is a capital investment in predictable grading and operational continuity.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

A Bespoke Coke Vibration Screen is a heavyduty industrial screening machine specifically designed for the sizing, especulación, or dedusting of metallurgical coke (cold or hot) and petroleum coke. Engineered from the ground up for this application, it replaces generic screens that fail under abrasive loads.

Flujo de trabajo operativo:
1. Alimentación controlada: Coke is introduced via a regulated feed chute onto the screen’s inlet section, distributing load across the full deck width.
2. HighIntensity Stratification: A precisely tuned vibratory mechanism (typically dual eccentric shaft or bruteforce design) imparts a linear or elliptical motion, aggressively stratifying material. Fines are forced downward to contact the deck.
3. Separación precisa: Stratified particles pass through accurately sized screen panel apertures (malla de alambre, poliuretano, o placa perforada), separating into defined size fractions (p.ej., +50milímetros, 50mm+25mm, 25milímetros).
4. Descarga eficiente: Sized fractions discharge via dedicated chutes into separate collection conveyors or bins for downstream processing.

Ámbito de aplicación: Cribado primario y secundario de coque metalúrgico. (blast furnace foundry), anodegrade petroleum coke, calcined coke. Suitable for sinter feed preparation and coke breeze recovery.
Limitaciones: Not designed for wet screening processes or as a replacement for crushers. Maximum feed temperature and particle size are defined by specific material specifications.

3. CARACTERÍSTICAS PRINCIPALES

Sistema de cubierta modular | Base técnica: Boltin panel subframes with tensioning rails | Beneficio operativo: Enables rapid changeover of worn screen media (<4 horas frente a. 12+), minimizing downtime for maintenance crews. | Impacto del retorno de la inversión: Reduces labor costs per changeout by ~60% and increases annual available production time.

Hot Coke Design Package | Base técnica: Internal aircooled bearing housings & heatresistant seals | Beneficio operativo: Allows continuous operation with coke feed up to 250°C without bearing lubrication failure or seal degradation. | Impacto del retorno de la inversión: Eliminates costly cooling periods before screening, increasing line throughput by maintaining process flow.

AntiBlinding & Wear Systems | Base técnica: Integrated ball tray decks or tensioned wire mesh with polyurethane cleaners | Beneficio operativo: Continuous microimpact dislodges sticky particles; wearresistant liners on decks/sideplates extend service life in highabrasion zones. | Impacto del retorno de la inversión: Maintains nearoriginal capacity over longer campaigns; reduces consumable parts expenditure by 3040% anualmente.

Dynamically Tuned Vibratory Frame | Base técnica: Análisis de elementos finitos (FEA) distribución de tensión optimizada & isolation spring system | Beneficio operativo: Contains vibratory forces within the screen body; minimizes harmful transmission to supporting structures (<90% isolation efficiency). | Impacto del retorno de la inversión: Protects civil foundation investments and eliminates ancillary structural repairs.

Diseño encapsulado en polvo | Base técnica: Gasketed covers & dusttight discharge spouts with inspection ports | Beneficio operativo: Contains coke dust at transfer points, improving site air quality and reducing housekeeping labor. | Impacto del retorno de la inversión: Lowers environmental compliance risk and reduces cleanuprelated operational delays.

Condition Monitoring Prep | Base técnica: Preinstalled sensor pads (vibración, temperatura) on bearings with external junction box | Beneficio operativo: Facilitates easy integration into predictive maintenance programs for early fault detection. | Impacto del retorno de la inversión: Previene fallas catastróficas en los rodamientos; enables planned shutdowns, avoiding 70+ hours of unplanned downtime per incident.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Generic Screen) | Solución de criba vibratoria de coque a medida | Ventaja (% Mejora) |
| : | : | : | : |
| Vida útil del panel de cubierta| 36 months under abrasive load| 814 months with applicationspecific media| +130% a +150% |
| Eficiencia de detección| ~85% for 25mm separation| Consecuentemente >92% for same separation| +8% ganancia absoluta |
| Tiempo de inactividad anual para mantenimiento de pantalla| 120180 horas (inspecciones, cambios)| 4060 horas (diseño modular)| 65% reducción |
| Consumo de energía por tonelada cribada| Base (100%)| Masa optimizada & conducir la eficiencia| 15% reducción |
| MTBF del rodamiento (Tiempo medio entre fallos)| ~12,000 hours in harsh service| >20,000 hours with cooling/sealing package| +67% mejora |

Screening Efficiency defined as ratio of correctly sized undersize material recovered vs. total undersize in feed.

5. ESPECIFICACIONES TÉCNICAS

Clasificación de capacidad: dependiente del modelo; rango estándar de 200 MTPH a 1,200 MTPH of bulk coke (80 lbs/ft³).
Unidad motriz: Dual eccentric shaft mechanism with greaselubricated spherical roller bearings. Alternative bruteforce designs available for highcapacity scalping.
Requisitos de energía: 15 kW a 55 kilovatios del motor (400V/50 Hz o según lo especificado), IP66 rated.
Configuración de la plataforma: Soltero, doble, or tripledeck layouts based on cut points.
Opciones de medios de pantalla: Malla de alambre de acero con alto contenido de carbono (hotgalvanized), paneles modulares de poliuretano, perforated manganese steel plates.
Marco estructural: Heavyduty carbon steel plate construction with internal ribbing; shotblasted and coated with industrial epoxy paint system.
Dimensiones físicas (Typical DoubleDeck): Length ~7m x Width ~2.5m x Height ~3m (excluding supports).
Entorno operativo: Diseñado para temperaturas ambiente de 20°C a +50°C; capable of processing material up to 250°C with hot package.

6. ESCENARIOS DE APLICACIÓN

[Steel Mill Blast Furnace Feed] Desafío: A major integrated steelmaker experienced high variability in blast furnace coke size fraction (50mm+25mm), leading to irregular gas flow and increased fuel rate penalties estimated at €500k annually.Solución: Implementation of a tripledeck bespoke coke vibration screen with precise aperture control ahead of the furnace bins.Resultados: Achieved consistent sizing with <3% deviation in target fraction; reduced furnace fuel rate by 2%. Payback period was under 18 months via fuel savings alone.

[Planta de calcinación de coque de petróleo] Desafío: Anodegrade calciner needed to remove all 8mm fines from final product but faced rapid blinding of standard screens from residual volatiles.Solución: Installation of a bespoke linear motion screen featuring antiblinding ball trays and directheated deck panels.Resultados: Sustained screening efficiency above 94%; eliminated manual deck cleaning shifts; increased saleable product yield by an estimated 4%.

7. CONSIDERACIONES COMERCIALES

Our Bespoke Coke Vibration Screens are offered in three primary tiers:
1. (Nivel básico): Standard Duty Screens, engineered core components with selectable media options—ideal for lowertonnage operations processing cooled coke.
2. (Nivel recomendado): HeavyDuty Performance Screens, includes all core features listed above—the standard solution for most highvolume metallurgical applications requiring reliability.
3. (Nivel Premium): SevereDuty Engineered Systems, includes full FEA analysis report customised feed/discharge hoods advanced instrumentation packages—specified for greenfield sites maximum operational data capture

Optional features include variable frequency drives process control integration custom skid bases extended warranty packages

Financing options include capital purchase lease agreements operating leases tailored support service packages provide scheduled inspections parts supply

8.Preguntas frecuentes

Q1 Is your bespoke vibration screen compatible existing conveyor feed hoppers
Our engineering team will review your existing layout interface drawings We design custom inlet transition sections flanges ensure a proper fit minimal retrofit required during installation

P2 ¿Cuál es el cronograma típico de puesta en servicio de la instalación?
From arrival site mechanical installation electrical connection dry run commissioning typically requires days supervised our engineer Delivery lead times vary based specification

Q3 How does this equipment impact overall plant noise levels
Properly installed isolated screens operate within dB(A) range at meter distance meeting typical industrial environmental standards Acoustic enclosures are available option where required

Q4 What are payment terms delivery
Standard terms progress payment upon order confirmation payment prior shipment balance due upon completion Factory Acceptance Test Major projects may qualify structured milestone payments

Q5 Do you provide wear parts ongoing technical support
We maintain comprehensive inventory critical wear parts offer guaranteed hour dispatch key components Support packages include remote diagnostics annual health checks technician dispatches