1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Is your coke screening operation plagued by persistent, costly inefficiencies? Para gerentes de planta y contratistas de ingeniería, the challenges of screening bulk metallurgical coke directly impact throughput, calidad del producto, and bottomline profitability. Los obstáculos operativos comunes incluyen:

Cegador & Continuar: Fine coke breeze and moisture cause screen mesh blinding, reduciendo el área de detección efectiva. Simultáneamente, undersize material carries over with the product stream, contaminating blast furnace feed and degrading its performance.
Tiempo de inactividad excesivo por mantenimiento: The abrasive nature of coke accelerates wear on screen decks, placas laterales, and exciters. Frequent component replacement leads to unplanned downtime and high spare parts inventories.
Separación de multas ineficiente: Inadequate separation of the 010mm fraction results in lost revenue from breeze sales and inefficient recycling within the coke plant.
Fatiga estructural & Falla: High Gforces from traditional vibrators transfer damaging stress to the screen body and support structure, leading to weld cracks and catastrophic frame failures.
Alto consumo de energía: Inefficient drive systems and oversized motors run continuously, contributing to significant, nonproductive power costs.

Are you seeking a solution that reduces downtime by 30% or more while ensuring consistent product sizing? The answer lies in selecting a coke vibration screen engineered specifically to overcome these materialspecific challenges.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The equipment in focus is a heavyduty Coke Classification Vibrating Screen, designed for highcapacity sizing of hot or cold metallurgical coke (25mm 80mm) from oven discharge and the subsequent separation of coke breeze (0mm 10mm).

Flujo de trabajo operativo:
1. Alimentar & Distribución: Bulk coke is uniformly fed onto the robust feed box, which distributes the material across the full width of the primary screen deck.
2. Dimensionamiento primario: A highstrength wire mesh or punch plate deck performs the primary separation, allowing undersize material (breeze and small fractions) to pass through.
3. Evaluación secundaria & Fines Removal: A second deck further refines the separation, ensuring maximum recovery of marketable coke breeze.
4. Descargar: Correctly sized foundry or blast furnace coke discharges from the screen end, while separated fines are collected via a dedicated chute for processing or sale.

Ámbito de aplicación & Limitaciones:
This equipment is designed for dry or slightly moist coke screening in fixed plant installations. It is not suitable as a replacement for rotary breakers or for handling highly sticky materials without pretreatment. Maximum lump size should not exceed 150% of the nominal top deck aperture.

3. CARACTERÍSTICAS PRINCIPALES

Sistema de cubierta modular | Base técnica: las bolas, pretensioned panel design with polyurethane side tensioning strips | Beneficio operativo: Individual deck sections can be replaced in under 2 hours without welding or specialized tools, minimizing downtime for maintenance. | Impacto del retorno de la inversión: Reduces screen cloth changeout time by up to 60%, aumentar directamente la disponibilidad de la planta.

Tecnología de accionamiento DualMass | Base técnica: Two synchronized counterrotating masses generating a linear stroke | Beneficio operativo: Transfers dynamic forces into the screening motion rather than the support structure; allows for lower horsepower motors due to efficient energy transfer. | Impacto del retorno de la inversión: Cuts structural maintenance costs by an estimated 40% and reduces operational energy consumption by 1525%.

Paquete de revestimiento resistente a la abrasión | Base técnica: Bolton wear plates made from AR400 steel at all critical impact points (caja de alimentación, labios de descarga) | Beneficio operativo: Protects the main screen frame from wear, extending its service life beyond 10 years under typical conditions. | Impacto del retorno de la inversión: Eliminates need for frequent frame repair or replacement, providing a predictable longterm asset cost.

Environmental Sealing System | Base técnica: Multistage labyrinth seals combined with durable rubber dust curtains at transfer points | Beneficio operativo: Contains dust emissions at source, improving site environmental compliance and operator health conditions. | Impacto del retorno de la inversión: Lowers costs associated with airborne particulate control and reduces housekeeping labor.

Tuned Spring Isolation | Base técnica: Computermodeled coil spring or rubber shear mount system matched to screen weight and operating frequency | Beneficio operativo: Aísla hasta 95% of dynamic vibration from the supporting structure, preventing damage to building foundations and adjacent equipment. | Impacto del retorno de la inversión: Eliminates secondary structural costs and prevents costly vibrationinduced failures in plant infrastructure.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | Coke Vibration Screen Solution | Ventaja (% mejora) |
| : | : | : | : |
| Tiempo de reemplazo del panel de cubierta| 68 horas (welded) | <2 horas (bolted modular) | ~70% más rápido |
| Vida de fatiga estructural| 35 years before major repair| 8+ years with protected frame| >100% aumentar |
| Eficiencia de detección (Breeze Removal)| ~85% efficiency| Consecuentemente >92% eficiencia| ~8% more product recovery |
| Operating Noise Level| 95105 dB(A) y 1m| <85 dB(A) y 1m| ~15 dB reduction |
| Annual Power Consumption| Base (100%) for same duty| Reduced motor size + conducción eficiente| 1525% reducción |

5. ESPECIFICACIONES TÉCNICAS

Clasificación de capacidad: dependiente del modelo; rango estándar de 300 MTPH a 1,200 MTPH of bulk coke (bulk density ~0.5 t/m³).
Requisitos de energía: Driven by dual lowvoltage AC motors (p.ej., 2 incógnita 11 kW a 2 incógnita 30 kilovatios), depending on model size and stroke configuration.
Especificaciones de materiales:
Marco: Acero al carbono de alta resistencia (S355JR), aliviar el estrés.
Cubiertas: Options include highcarbon steel wire mesh (65Minnesota), HARDOX® punch plates, or polyurethane panels.
Wear Protection: AR400 steel liners standard at all impact zones.
Dimensiones físicas: Typical singledeck unit footprint ranges from (l)6m x (W.)2.5m x (h)1.8m to (l)9m x (W.)3.5m x (h)2metro.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +50°C; capable of handling hot coke up to ~200°C with appropriate deck material selection.

6. ESCENARIOS DE APLICACIÓN

Integrated Steel Plant Coke Oven Battery Discharge

Desafío: A major steel producer faced severe blinding on their existing screens due to residual moisture in quenched coke. This caused frequent overloads on downstream crushers and inconsistent blast furnace feed sizing (+/15variación mm).
Solución: Implementation of two parallel heavyduty linear motion Coke Vibration Screens featuring nonblinding balltray decks on the fines removal section.
Resultados: Screening efficiency stabilized at ≥94%. Oversize contamination was eliminated (<1%), protecting crusher integrity. The consistent product sizing contributed to a documented ~3% improvement in blast furnace burden permeability.

Merchant Coke Producer – Breeze Recovery

Desafío: A merchant plant was losing significant revenue due to poor fines capture; an estimated 810% of saleable breeze was being incorrectly routed back into crusher feed circuits as "circulating load."
Solución: Retrofitting a dedicated Coke Vibration Screen with a finemesh secondary deck into their product classification circuit postcrushing.
Resultados: Breeze recovery increased from ~82% to over 95%, creating an additional revenue stream exceeding project payback within one year based on market prices for fuelgrade fines.

7.CONSIDERACIONES COMERCIALES

Nuestras cribas vibratorias de coque se ofrecen en tres niveles principales:
Serie de servicio estándar: For capacities up to ~500 MTPH with robust base specifications; ideal para plantas más pequeñas o ciclos de trabajo menos severos.
Serie de servicio pesado (>500 MTPH): Our most common specification featuring all core technologies listed above; designed for continuous operation in integrated steel plants.
Soluciones de ingeniería personalizadas: For unique layouts requiring multiple discharge points specific grades like nut coke separation

Las características opcionales incluyen:
Enclosed designs with integrated dust extraction flanges
Stainless steel components for highly corrosive environments
Sensores de monitoreo de condición avanzados
Variadores de frecuencia

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including guaranteed spare parts availability Financing options including leasing are available through our partners

Preguntas frecuentes

What is your typical lead time?

For standard HeavyDuty Series models lead time is typically between weeks depending on current production schedules Custom engineered solutions require additional engineering time

Are your screens compatible with our existing chutes?

Our engineering team will review your existing layout drawings We provide detailed interface specifications including loads connection points ensuring seamless integration into your current transfer system

How do you guarantee performance?

Performance guarantees are based on agreedupon feed material characteristics We provide certified capacity curves based on laboratory testing data Guarantees typically cover throughput capacity under specified conditions

What does commissioning involve?

Our standard package includes supervision installation mechanical alignment initial startup process tuning We ensure correct operation before handover Documentation includes detailed manuals training materials

What are payment terms?

Standard commercial terms involve progress payments tied key milestones Typically % upon order % before shipment balance upon completion satisfactory commissioning Letters credit accepted Financing options available upon request