1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Su operación de detección de coque está plagada de persistentes, costosas ineficiencias? For plant managers and engineering contractors in the metallurgical coke and foundry coke sectors, the vibration screen is a critical yet problematic node. Los desafíos comunes incluyen:

Cegador & Continuar: Moisture and fine coke dust adhere to screen decks, blinding apertures and forcing undersized material to carry over. This reduces screening efficiency by 1530%, contaminates product grades, and directly impacts blast furnace burden consistency.
Tiempo de inactividad excesivo para mantenimiento: Traditional screens require frequent shutdowns for deck cleaning, tensar, or panel replacement. Unplanned downtime for a primary coke screen can cost over $5,000 por hora en producción perdida.
Fatiga estructural & Fracaso prematuro: The abrasive nature of coke and the highcycle operation induce metal fatigue in side plates, cross members, and welds. This leads to catastrophic frame cracks, often within 1218 months of service, necessitating a full rebuild or replacement.
Alto consumo de energía & Ruido: Inefficient drive systems and unbalanced mass designs consume excess power—a significant operational cost—while generating noise levels that exceed 90 dB(A), creating environmental and worker safety concerns.

Are you seeking a vibration screen solution that delivers consistent product sizing with minimal downtime, engineered specifically for the harsh demands of coke classification?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The China Coke Vibration Screen is a heavyduty, linear motion vibrating screen designed for the highcapacity sizing and scalping of metallurgical (alto horno) coke and foundry coke. Engineered for robustness in highabrasion, highdutycycle environments, it ensures reliable separation of coke breeze from lump coke.

Flujo de trabajo operativo:
1. Alimentar & Distribución: Sized coke from the crusher or oven is fed onto the screen via a regulated feed chute onto a robust feed deck for even material distribution.
2. Estratificación & Separación: The dualshaft vibrator assembly generates a linear throwing motion, material estratificante. Demasiado grande (lump coke) travels across the deck surface to the discharge end, mientras que de tamaño insuficiente (brisa de coque) passes through the defined screen apertures.
3. Manejo del producto: Separated fractions are discharged via dedicated chutes—lump coke to blast furnace stockhouses or loading bays, and coke breeze to sintering plants or storage.

Ámbito de aplicación: Dimensionamiento primario (p.ej., separando >25mm from <25milímetros), scalpings of oven charge, dedusting of crushed coke. Not recommended for extremely sticky materials without specialized deck systems or for wet screening applications without design modifications.

3. CARACTERÍSTICAS PRINCIPALES

Sistema de cubierta modular | Base técnica: las bolas, pretensioned polyurethane or rubberclad steel panels | Beneficio operativo: Los paneles se pueden sustituir individualmente en menos de 30 minutos sin herramientas especializadas; reduced blinding characteristics | Impacto del retorno de la inversión: Cuts deck maintenance downtime by up to 70% versus bolteddown steel plate systems.

Vibrador sincronizado DualShaft | Base técnica: Two contrarotating eccentric masses connected by a synchronization gear | Beneficio operativo: Generates a pure linear motion for efficient material conveyance; allows for adjustable stroke through counterweight configuration | Impacto del retorno de la inversión: Provides consistent screening efficiency of 9295%, improving product yield and reducing recirculation load.

Construcción de marco robusto | Base técnica: Análisis de elementos finitos (FEA)optimized side plates with reinforced cross beams and continuous welds | Beneficio operativo: Withstands dynamic loads from both material impact and vibration forces; resists fatigue cracking | Impacto del retorno de la inversión: Extends operational lifespan beyond 60 months under severe duty, deferring major capital expenditure.

DustProtected Bearing Assembly | Base técnica: Labyrinth seals combined with grease purge system on vibrator bearing housings | Beneficio operativo: Effectively excludes abrasive coke dust from critical bearing components | Impacto del retorno de la inversión: Increases bearing service life to over 20,000 horas, eliminating a primary cause of unplanned stoppages.

EnergyEfficient Drive System | Base técnica: Direct coupled IE3class motors with flexible couplings | Beneficio operativo: Reduce las pérdidas de transmisión de energía.; operates at >94% motor efficiency | Impacto del retorno de la inversión: Lowers annual energy consumption by approximately 812% compared to standardefficiency drives with Vbelts.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | China Coke Vibration Screen Solution | Ventaja (% mejora) |
| : | : | : | : |
| Eficiencia de detección (dry coke) | 8588% | 9295%| +7% aumento promedio |
| Tiempo de cambio del panel de cubierta (cubierta completa) | 812 horas| 34 horas| ~65% de reducción |
| Vida útil del rodamiento del vibrador (L10) | ~12.000 horas| >20,000 horas| >66% extensión |
| Consumo de energía (per ton screened) Línea de base = 100%|100%|8892%|812% reducción |
| Vida de fatiga estructural (to first major crack)|1824 meses|60+ meses|>150% mejora |

5. ESPECIFICACIONES TÉCNICAS

Capacidad / Clasificación: Modelos disponibles desde 50 TPH a 1,200 Capacidad de TPH para cribado de coque seco.
Requisitos de energía: Motor de accionamiento desde 5.5 kW a 45 kilovatios (400V/50Hz/3Ph standard). IE3 highefficiency rating.
Especificaciones de materiales: Placas laterales & marco: Q345B carbon steel; Cubiertas de pantalla: Hardox 400 wear liners on feed zone; Deck panels: Tensionable polyurethane (PU) or rubberclad steel; Vibrator shafts: 42Acero aleado CrMo.
Dimensiones físicas: Typical unit sizes range from 1.2m x 3m singledeck up to 2.4m x 6m doubledeck configurations.
Rango de operación ambiental: Temperatura ambiente: 20°C a +45°C; Designed for dustladen atmospheres; Weather covers available.

6. ESCENARIOS DE APLICACIÓN

[Metallurgical Coke Plant Primary Sizing] Desafío: A major steel plant’s existing screens suffered rapid deck blinding due to residual moisture (~4%), causing inconsistent lump/breeze split and excessive recrushing of onspec material. Downtime for manual cleaning occurred weekly.

[Foundry Coke Producer Product Dedusting] Desafío: A producer needed to remove fines (<10milímetros) from crushed foundry coke to meet strict customer specifications but experienced high noise levels and frequent spring failures on old screens.

[Coke Wharf Screening Station] Desafío: A port facility required robust equipment for final screening before ship loading but faced constant structural weld failures on screens due to saltair corrosion combined with abrasive wear.

[Metallurgical Coke Plant Primary Sizing] Solución: Implementation of two large linear China Coke Vibration Screens equipped with nonblinding PU panel systems on the primary sizing duty.

[Foundry Coke Producer Product Dedusting] Solución: Installation of a midsized China Coke Vibration Screen with an enclosed base pan and rubber shear spring mounts.

[Coke Wharf Screening Station] Solución: Deployment of heavyduty screens featuring hotdip galvanized frames postwelding alongside AR steel liners at all impact points.

[Metallurgical Coke Plant Primary Sizing] Resultados: Screening efficiency stabilized at ≥94%. Deckrelated downtime reduced by over $150k annually in labor and lost production savings.

[Foundry Coke Producer Product Dedusting] Resultados: Fines content consistently below spec threshold (<2%). Noise at operator stations reduced by ~10 dB(A). Spring replacement intervals extended from quarterly to biennial.

[Coke Wharf Screening Station] Resultados: No structural integrity issues reported after three years of continuous operation

7 CONSIDERACIONES COMERCIALES

Equipment pricing is tiered based on size capacity construction features:
• Standard Duty Series For capacities upto300TPH ideal secondary/check screening
• HeavyDuty Series For primary sizing duties(300–800TPH)
• Extra HeavyDuty Series For largescale plants(800+TPH)

Las características opcionales incluyen:
• Enclosed dust hoods
• Heating systemsfor decks
• Vibration monitoring sensors
• Different panel materials(wire mesh rubber PU)
• Special corrosion protection coatings

Paquetes de servicios disponibles:
• Basic Package Includes commissioning spare parts kit
• Planned Maintenance Package Covers annual inspection parts discounts
• Full Service Contract Includes predictive maintenance basedon sensor data

Opciones de financiación:
Direct leasing arrangements through partner financial institutions are available as well as milestonebased payment plansfor large projects

8 Preguntas frecuentes

Q1 Are your screens compatible with our existing feed conveyor discharge chutework?
Field data shows our engineering team can provide detailed interface drawings ensuring mechanical compatibility We typically require your existing layout dimensions load data

Q2 What isthe expected impacton our overall plant throughput?
By maintaining consistent screening efficiency this solution minimizes bottlenecksin your crushing circuit Industry testing demonstrates plants reporta3–5% increasein usable product output dueto reduced recirculation load

Q3 Do you offer different motion types like circularor elliptical?
For efficient conveyanceof abrasive granular materialslikecoke linear motionis themost effective standard Our design focuseson optimizingthis motionfor maximum longevityand performance

Q4 What arethe standard commercial terms lead time payment structure?
Standard deliveryis14–16weeksfrom orderconfirmation Payment termsare typically30%advance70%against shipment copyof billoflading Other termscanbe negotiatedfor turnkey projects

Q5 Howis implementation handled? Do you providesupervision?
We providecomprehensive foundation drawings electrical schematics Our standard offering includes remote commissioning support Optional onsite supervisionby our engineersis availableas partofa service package