1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Is your coke handling operation struggling with inconsistent product quality, generación excesiva de multas, and unplanned maintenance cycles? Inefficient screening directly impacts your bottom line through lost product, higher energy consumption in downstream processes, and costly downtime for screen deck replacements. Considere estos desafíos comunes:
Blinding & Carryover: Moisture or sticky fines blind screen meshes, reducing effective screening area and forcing oversized particles into the finished product, compromising quality.
Premature Deck Failure: The abrasive nature of hot coke accelerates wear on screen panels and support structures, llevando a frecuentes, disruptive shutdowns for replacements.
Inefficient Fines Separation: Inadequate separation results in valuable coke fines being lost to waste or oversized material overworking crushers, increasing power costs and wear.
Excessive Vibration Transmission: Poorly isolated vibration damages support structures and adjacent equipment, creating safety concerns and secondary maintenance issues.

Are you seeking a solution that maximizes uptime, protects product specification integrity, and reduces your total cost of ownership per ton screened?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The Coke Vibration Screen is a heavyduty industrial screening machine designed for the hightemperature, highabrasion separation of metallurgical coke. Its primary function is to reliably separate crushed coke into precise size fractions (p.ej., blast furnace coke, nut coke) while removing fines.

Flujo de trabajo operativo:
1. Introducción al feed: Crushed coke is uniformly distributed onto the feed end of the screen via a chute or conveyor.
2. Stratified Vibration: A highGforce vibratory motion stratifies the material bed, forcing fines and nearsize particles down to the screen media surface.
3. Size Separation: Particles smaller than the aperture pass through (tamaño insuficiente), while larger particles travel across the deck as oversize.
4. Descargar: Separated fractions are discharged via dedicated chutes for further processing or shipment.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal for dry screening of hot or cold metallurgical coke in coke plants, steel mills, and foundries. Suitable for sizing (single or multideck) and dedusting applications.
Limitaciones: Not designed for wet screening or slurry applications. Maximum feed temperature typically capped by seal and bearing specifications (commonly up to 150200°C). Extremely sticky materials may require pretreatment or specialized deck cleaning systems.

3. CARACTERÍSTICAS PRINCIPALES

HeavyDuty Box Beam Deck Support | Base técnica: Reinforced structural design with continuous weldment | Beneficio operativo: Eliminates deck flexing under load for consistent stratification; withstands impact from large coke lumps | Impacto del retorno de la inversión: Extends screen cloth life by up to 30%, reducing part change frequency and downtime.

HighTemperature / Revestimientos resistentes a la abrasión | Base técnica: Bolton wear plates at feed points made from AR400 or equivalent steel | Beneficio operativo: Protects main deck structure from direct impact and abrasion damage | Impacto del retorno de la inversión: Lowcost liner replacement vs. full deck repair; maintains structural integrity for years.

DualVibrator Drive System | Base técnica: Two synchronized externallymounted vibrator motors generating linear motion | Beneficio operativo: Simplified maintenance access; balanced force distribution; easy amplitude adjustment via motor weights | Impacto del retorno de la inversión: Higher reliability than shaftdriven designs; modular motor replacement minimizes downtime.

MultiStage Rubber Isolation System | Base técnica: Layered rubber shear mounts or coil spring isolators | Beneficio operativo: Absorbs over 95% of dynamic forces before they reach the support structure | Impacto del retorno de la inversión: Eliminates costly structural reinforcement needs; protects surrounding equipment from vibration damage.

QuickChange Deck Tensioning System | Base técnica: Modular tensioning rails with bolton wedge clamps | Beneficio operativo: Allows single operator to change screen panels in under one hour without specialized tools | Impacto del retorno de la inversión: Reduces planned maintenance window by over 60%, aumento de la disponibilidad de la planta.

DustEncapsulated Bearing Housings | Base técnica: Labyrinth seals with grease purge fittings on vibrator shaft bearings | Beneficio operativo: Prevents ingress of fine abrasive coke dust into bearing assemblies | Impacto del retorno de la inversión: Extends critical bearing service life by 23x, preventing catastrophic drive failure.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | Coke Vibration Screen Solution | Ventaja (% Mejora) |
| : | : | : | : |
| Screen Media Life (Desgaste abrasivo) | Standard woven wire panels on flat decks | Optimized tensioned polyurethane panels on rigid box beam supports| +2535% longer operational life |
| Tiempo de inactividad por mantenimiento (Deck Change) ~40 sqm deck| 46 hours with multiple personnel| <2 hours with standard crew| 60% downtime per changeout |
| Vibrational Force Transmission to Structure| A menudo excede 25% of dynamic force transmitted| <5% transmitted via multistage isolation| 80% reduction in structural stress |
| Eficiencia Energética (Screening Specific)| Fixed Gforce often requires overspecification| Adjustable amplitude matches material flow rate precisely| Arriba a 15% energy use in variable conditions |

5. ESPECIFICACIONES TÉCNICAS

Capacidad & Clasificación: dependiente del modelo; typical range from 200 a 1,200 metric tons per hour of dry coke.
Cubiertas de pantalla: Soltero, doble, o configuraciones de tres pisos. Standard effective screening area from 10㎡ to 40㎡.
Potencia motriz: Electrically powered vibrator motors totaling 15 kW a 75 kW depending on machine size and required Gforce.
Materiales de construcción: Main frame – carbon steel ST37/44. Wear surfaces – replaceable AR400 steel liners (mín.. 400 Brinell). Standard screen media – tensioned polyurethane or hardened steel wire cloth.
Dimensiones físicas: Length range: ~4m to ~9m; Width range: ~1.5m to ~3m; Altura (varies with configuration): ~2m to ~4m.
Entorno operativo: Diseñado para temperaturas ambiente de 20°C a +50°C, handling material temperatures up to 180°C continuously with specified seals.

6. ESCENARIOS DE APLICACIÓN

Steel Mill Coke Handling Plant

Desafío: A major integrated steel mill experienced rapid blinding of wire mesh screens when processing coke with elevated moisture content (~8%), causing oversize contamination in blast furnace feed every 1012 días.
Solución: Implementation of a tripledeck Coke Vibration Screen fitted with nonblinding polyurethane screen panels featuring tapered apertures and a highGforce linear drive system.
Resultados: Screening intervals extended to over 45 days between scheduled cleanings. Oversize contamination reduced by >98%, ensuring consistent blast furnace burden permeability.

Merchant Coke Producer

Desafío: Excessive generation of 5mm fines during final product screening was eroding profit margins due to product degradation and lost saleable tonnage.
Solución: Installation of a doubledeck Coke Vibration Screen optimized for precise cutpoint separation at 6mm and 25mm using a dualvibrator drive system for stable stratification control.
Resultados: Fines generation (5milímetros) reduced by an average of 22%. This resulted in an increase in saleable nut coke (+6mm/25mm) fraction yield worth approximately €120k annually at prevailing prices.

7. CONSIDERACIONES COMERCIALES

Our Coke Vibration Screens are offered across three primary tiers:
1. Standard Duty Range: For lowercapacity plants (<500 tph), featuring robust construction with standard liners and isolation systems.
2. HeavyDuty Range: For hightonnage operations (>500 tph), incorporating enhanced boxbeam decks, premium abrasion liners (AR500), and advanced multistage isolation as standard.
3. Custom Engineered Solutions: For unique layouts or extreme material conditions (p.ej., very high temperature).

Las características opcionales incluyen:
Enclosed dust hoods
Airblast or balltray antiblinding systems
Variable frequency drives for motor control
Condition monitoring sensors

Service packages are available from basic commissioning support up through comprehensive multiyear planned maintenance agreements covering inspections, wear parts kits, y soporte técnico prioritario.

Financing options include capital purchase as well as operational leasetoown models designed to align payments with your production cycles.

8.Preguntas frecuentes

Q1 Are these screens compatible with our existing feed chutes and discharge conveyors?
A Yes—our engineering team provides detailed interface drawings during quotation based on your existing layout dimensions required belt centers heights ensuring fit within your current infrastructure

Q2 What is the expected operational impact during installation?
A Minimal Field data shows typical installation including foundation preparation mechanical erection electrical connection commissioning requires a planned outage window days depending on site readiness We manage this process turnkey basis

Q3 How does this solution address different moisture levels in feed?
A The combination adjustable Gforce non blinding polyurethane panels effectively handles typical moisture variations % For consistently higher levels we recommend optional integrated air blast cleaning system maintain efficiency

Q4 What are standard commercial terms lead time payment?
A Standard delivery lead time weeks ex works following design approval Payment terms typically progress payment upon order confirmation balance prior shipment We also accept irrevocable letters credit

Q5 Do you provide spare parts kits?
A Yes We offer recommended initial spare parts kits containing critical wear items gaskets seals tensioning components based on estimated annual consumption reducing unplanned downtime sourcing parts

Q6 Can you assist performance validation before purchase?
A Absolutely We provide detailed performance calculations based your specific material test data can arrange testing existing units pilot scale facility upon request validate capacity separation efficiency claims