Coke Vibration Screen ODM Manufacturer
1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR
Is your coke handling operation plagued by persistent bottlenecks, costos de mantenimiento excesivos, y calidad del producto inconsistente? Para gerentes de planta que supervisan el cribado de coque, common challenges directly impact the bottom line:
Cegador & Falta del tiempo: Bien, Las partículas de coque húmedas se adhieren a las plataformas de criba., causando cegamiento rápido. This reduces effective screening area by up to 40%, forcing frequent shutdowns for manual cleaning and slashing throughput.
Desgaste prematuro & High OPEX: La naturaleza abrasiva del coque metalúrgico acelera el desgaste de los paneles de criba, cubiertas, y excitadores. Unplanned component replacements and associated labor can increase annual maintenance budgets by 25% o más.
Separación de multas ineficiente: Inadequate vibration dynamics lead to poor segregation of breeze (coke fines under 10mm). This results in product contamination, lost revenue from missized material, and potential downstream process issues.
Fatiga estructural & Vibration Transmission: High Gforces needed for effective screening transmit damaging vibrations to the support structure and surrounding equipment, leading to cracks, foundation issues, and safety concerns.
Are you searching for a robust screening solution that delivers consistent uptime, lowers total cost of ownership, and ensures precise size separation for your coke product?
2. DESCRIPCIÓN GENERAL DEL PRODUCTO
The Coke Vibration Screen is a heavyduty industrial screening machine engineered for the highcapacity sizing and scalping of metallurgical coke in battery, quenching, and sorting stations. Its core function is to separate crushed coke into precise fractions (p.ej., coque de alto horno, coca de nuez, brisa) while efficiently removing fines.
Flujo de trabajo operativo:
1. Alimentar & Distribución: Crushed coke is uniformly fed onto the inlet end of the inclined screen deck via a chute or feeder.
2. Estratificación & Separación: Alta intensidad, linear or elliptical vibration stratifies the material bed. Smaller particles pass through precisely sized deck apertures; oversized particles travel across the deck surface.
3. Descargar: Correctly sized fractions are discharged via separate outlets—oversize to crushers for recirculation or as product, undersize as breeze or product—ensuring a clean separation.
Ámbito de aplicación: Primary sizing of metallurgical coke after crushing; scalping of oven discharge; dedusting and fines removal; recovery operations.
Limitaciones: No diseñado para materiales pegajosos sin tecnología de plataforma especializada; maximum feed size is constrained by deck opening and machine design; requires controlled feed rate for optimal efficiency.
3. CARACTERÍSTICAS PRINCIPALES
Sistema de plataforma de servicio pesado | Base técnica: Modular polyurethane or rubberclad steel panels with reinforced fixing | Beneficio operativo: Dramatically increased service life under abrasive conditions; reduced noise levels (by ~10 dBA); panels are easily replaced in sections minimizing downtime | Impacto del retorno de la inversión: Cuts panel replacement costs by up to 60% over traditional woven wire decks.
AntiBlinding Technology | Base técnica: Integrated ball tray decks or ultrasonic screen mesh cleaning systems | Beneficio operativo: Continuous microimpact dislodges lodged particles near aperture openings maintaining nearoriginal open area | Impacto del retorno de la inversión: Sustains design capacity throughput reduces cleaning downtime by over 70%.
Balanced Elliptical Vibration | Base técnica: Twin shaft exciter with outofphase synchronized weights generating an elliptical throw pattern | Beneficio operativo: Optimized material travel speed with sharp stratification enhances separation accuracy especially for midrange sizes (1030milímetros) | Impacto del retorno de la inversión: Improves product purity by an average of 15% reducing recrush load and maximizing premium fraction yield.
Diseño cerrado hermético al polvo | Base técnica: Gasketed side plates and dust hood connections with integral skirt boards | Beneficio operativo: Contains airborne coke dust at transfer points improving site air quality meeting environmental standards | Impacto del retorno de la inversión: Lowers housekeeping costs mitigates health safety risks avoids potential regulatory noncompliance fines.
Marco de vibración aislado | Base técnica: Dynamic vibration isolators (rubber or spring) between the vibrating body and stationary base frame | Beneficio operativo: Absorbe más 95% of dynamic forces preventing transmission to supporting structures eliminates fatigue failures | Impacto del retorno de la inversión: Removes need for massive dedicated foundations reduces installation time capital cost protects plant infrastructure integrity.
Centralized Greasing Lube System | Base técnica: Manifold with lines feeding all major bearing points from a single access port | Beneficio operativo: Enables safe rapid lubrication during brief pauses extends bearing life under highload hightemperature conditions | Impacto del retorno de la inversión: Standardizes preventive maintenance intervals reduces bearing failure rates by an estimated 40%.
4. VENTAJAS COMPETITIVAS
| Métrica de rendimiento | Estándar de la industria | Coke Vibration Screen Solution | Ventaja (% mejora) |
|||||
| Deck Panel Lifespan | Woven wire mesh lasts 23 meses bajo fuerte abrasión | Polyurethaneclad modular panels last 812 meses | +300% vida útil |
| Eficiencia de detección | ~85% efficiency for midsize separation due to blinding | Mantiene >92% efficiency via antiblinding systems | +78% eficiencia sostenida |
| Tiempo de inactividad por mantenimiento | 812 hours monthly for cleaning bearing checks panel replacement
| Energy Consumption per Ton ~0.12 kWh/ton processed
| Breeze (10milímetros) Contamination in Product Fraction
5. ESPECIFICACIONES TÉCNICAS
Capacidad / Clasificación: Depende del modelo de 200 TPH por encima 1500 TPH throughput capacity standard designs available
Requisitos de energía: Drive motor range from 7.5 kW a 45 kW depending on screen size mass excitation force
Especificaciones de materiales: Highstress frame components S355JR steel side plates wear liners Hardox®400 Abrasionresistant polyurethane rubber composite deck materials
Dimensiones físicas (Modelo típico): Deck Size (L x A): 3m x1 .5m Overall length:~4 .2m Overall width:~2 .8m Height:~1 .6m Weight:~6500kg
Rango de operación ambiental: Temperatura ambiente:20°C +50°C Feed material temperature upto120°C(máximo) Weather protection IP65 enclosure optional
6. ESCENARIOS DE APLICACIÓN
Metallurgical Coke Plant Blast Furnace Feed Preparation Challenge:: Existing screens blinded within hours due high moisture content in quenched coke causing severe bottleneck before furnace feed bins resulting in inconsistent size distribution affecting furnace efficiency
Solución:: Installation two large doubledeck Coke Vibration Screens equipped ball tray antiblinding decks isolated base frames
Resultados:: Screening availability increased from94%. Blast furnace feed consistency improved quantified as+/5mm size variation reducedby30%. Annual maintenance labor hours decreasedby1200
Coke Sorting Terminal Product Diversification Challenge:: Terminal needed produce three distinct saleable products(>50mm2550mm<25milímetros)from single feed stream but existing separator generated excessive fines(<10milímetros)in midrange fraction reducing its market value
Solución:: Implementation multislope Coke Vibration Screen with precision elliptical vibration finetuning deck tensioning system
Resultados:: Product purity each fraction achieved>95%. Revenue from midrange(2550milímetros)fraction increasedby18%due reduced fines content System handled variable feed rates without performance degradation
7. CONSIDERACIONES COMERCIALES
Niveles de precios de equipos: Entrylevel standard duty screens(starting~$25000);Heavyduty customengineered units($65000$200000+)based size configuration options
Características opcionales / Actualizaciones: Stainless steel construction critical areas hotmaterial handling kits spray bar systems different deck types(harps tensioned polyurethane etc.) variable frequency drives advanced condition monitoring sensors
Paquetes de servicios: Tiered annual maintenance contracts covering inspection parts discounts priority support Extended warranty available upto36months Comprehensive training programs operational maintenance staff included
Financing Options Available through partners include equipment leasing longterm rental purchase plans tailored capital expenditure cycles Project financing considered largescale installations
8. Preguntas frecuentes
Q1 How do we determine correct screen size deck configuration our specific capacity requirements?
Our engineering team requires your detailed feed rate particle size distribution(P80 D50)desired product splits moisture content This data allows us model recommend optimal machine specifications guarantee performance
Q2 Can this equipment integrate our existing PLC control system material handling network?
Yes standard designs include control panel compatible common industrial protocols(Profibus Ethernet/IP etc.) We provide necessary interface documentation facilitate integration your plant SCADA system
Q3 What typical installation timeline foundation requirements?
With isolated design foundation requirements less stringent than older screens Typical installation including positioning electrical mechanical connection commissioning takes510working days depending complexity Preinstallation foundation drawings issued advance
Q4 Are spare parts readily available what expected lead times?
We maintain strategic inventory critical wear parts(decks bearings exciters)at regional hubs Standard parts ship within48hours Custom components have lead times communicated upfront during purchase Longterm supply agreements ensure ongoing support
Q5 How does equipment handle variations feed rate material composition?
Robust design accommodates reasonable fluctuations Variable speed drive option allows operators adjust vibration intensity optimize performance realtime changing conditions ensuring consistent output quality