1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

¿Su operación de manipulación de coque está luchando contra cuellos de botella persistentes?, generación excesiva de multas, y costos de mantenimiento no planificados? Inefficient screening directly impacts your plant’s bottom line through lost product, aumento del consumo de energía para los procesos posteriores, y costosos tiempos de inactividad para el reemplazo de la plataforma de cribado. Are you currently facing these challenges?
Cegador & Continuar: Moisture and sticky fines blind screen meshes, reducing effective screening area and forcing material to carry over unscreened, contaminating your product fractions.
Desgaste excesivo & Mantenimiento: The abrasive nature of hot coke rapidly degrades standard screen panels and deck components, leading to frequent shutdowns for replacements and high spare parts inventories.
Inefficient Separation: Inconsistent vibration or inadequate screening area results in poor size distribution control, sending offspec material to crushers or battery bunkers, disrupting the entire production chain.
Fatiga estructural: The intense impact loads from coke discharge can cause premature failure of the screen body and support structures, risking major operational failure.

The right coke vibration screen is not just a separator; it’s a critical asset for throughput stability and product quality control.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The heavyduty coke vibration screen is a highcapacity, linear motion screening machine engineered for the primary sizing and scalping of metallurgical coke. It is designed to withstand extreme abrasion, impacto, and thermal stress in coke handling plants.

Flujo de trabajo operativo:
1. Alimentar & Distribución: Hot or cooled coke from a conveyor is discharged onto a robust feed box or plate, distributing the material evenly across the full width of the first screen deck.
2. Primary Stratification & Apresto: The powerful dualvibrator motor drive generates a linear throwing motion. Esta acción estratifica el lecho de material., forcing fines downward through the apertures of the upper deck(s) while conveying oversize toward the discharge end.
3. Fraction Separation: Múltiples niveles de cubierta (típicamente 2 o 3) with precisely sized screen media (rails, alambre tejido, or polyurethane panels) separate the coke into defined product streams (p.ej., coque de alto horno, coca de nuez, brisa).
4. Descargar: Sized fractions are discharged via separate chutes for transport to storage bunkers or downstream processes.

Ámbito de aplicación & Limitaciones:
Alcance: Ideal for primary screening of metallurgical coke after quenching or crushing; scalping of ovenrun coke; separation of coke breeze from larger fractions in byproduct recovery.
Limitaciones: Not designed as a dewatering screen for slurries. Maximum feed temperature is determined by specific component selection (p.ej., sellos resistentes al calor, motor isolators). Los materiales extremadamente pegajosos pueden requerir un tratamiento previo o sistemas especializados de limpieza de plataformas..

3. CARACTERÍSTICAS PRINCIPALES

Sistema de soporte de plataforma de servicio pesado | Base técnica: Reinforced crossmembers with abrasionresistant wear liners | Beneficio operativo: Protects the main frame from direct material impact, drastically extending structural life | Impacto del retorno de la inversión: Eliminates costly frame repairs; reduces lifetime structural maintenance costs by an estimated 6070%.

Accionamiento de vibrador doble contrarrotante | Base técnica: Two synchronized motors generating a pure linear force | Beneficio operativo: Provides consistent material travel speed and stratification without elliptical motion; minimal transmission wear | Impacto del retorno de la inversión: Ensures stable product sizing yearround; reduces drive maintenance compared to eccentric shaft designs.

QuickChange Screen Media System | Base técnica: Modular panel clamping with frontaccess tensioning | Beneficio operativo: Allows single operators to replace worn panels in under an hour without specialized tools | Impacto del retorno de la inversión: Cuts downtime for media changes by up to 75%, aumentar directamente la disponibilidad de la planta.

Advanced Isolation Mounting | Base técnica: Multilayered rubbercork or steel spring isolators tuned to machine frequency | Beneficio operativo: Absorbe más 95% of dynamic forces before they reach the support structure | Impacto del retorno de la inversión: Protects building infrastructure from vibration damage; eliminates secondary support costs.

Hot Material Construction Package | Base técnica: Heatdeflecting covers on vibrators, hightemp labyrinth seals on bearings, heatresistant paint systems | Beneficio operativo: Ensures reliable operation when handling hot coke directly from quench towers | Impacto del retorno de la inversión: Increases component lifespan in highheat applications by over 40%, protegiendo su inversión de capital.

Sistema de lubricación centralizado (Opcional) | Base técnica: Automated greasing lines feeding all critical bearing points on vibrator shafts | Beneficio operativo: Guarantees proper lubrication intervals in hardtoaccess areas under all operating conditions | Impacto del retorno de la inversión: Previene fallas catastróficas en los rodamientos; extends bearing service life by up to 50%.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Solución estándar de la industria | Nuestra solución de criba vibratoria de coque | Ventaja (% Mejora) |
| : | : | : | : |
| Vida útil del panel (Upper Deck) | Standard Hardox 400 Rails ~4 Months| Proprietary Alloy Cast Rails with Hardfacing ~9 Months| +125% vida útil |
| Eficiencia de detección (para la fracción objetivo)| ~8892% efficiency under load| Coherente >95% efficiency under load| +35 puntos porcentuales |
| Tiempo de inactividad anual para mantenimiento de pantalla| ~120150 horas/año| 50% reducción |
| Fuerza dinámica transmitida a la estructura| High transmission requiring reinforced foundations|95% reducción de la fuerza transmitida |
| Consumo de energía por tonelada cribada| Línea de base = 100%| Optimized mass/force balance reduces consumption by ~15%| 15% menor costo de energía |

5. ESPECIFICACIONES TÉCNICAS

Modelo Rango Capacidad: De 500 TPH por encima 2,500 Capacidad de rendimiento de TPH.
Cubiertas de pantalla: Típicamente 2 o 3 cubiertas; configuraciones personalizadas disponibles.
Potencia motriz: Motores vibradores duales que van desde 2 incógnita 15 kW a 2 incógnita 55 kW dependiendo del tamaño del modelo y del servicio.
Vibration Frequency/Frequency: Fixed frequency typically between 9001000 RPM; stroke adjustable via counterweight configuration.
Materiales de construcción: Main frame heavyduty steel plate (S355JR+). Wear surfaces AR400 steel liners. Screen media options include alloy cast rails (estándar), tensioned woven wire mesh, or modular polyurethane panels.
Dimensiones físicas (Modelo de ejemplo): Widths from 1.8m to 3.6m; lengths from 6m to over 11m overall.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +50°C. Specific hotduty packages allow handling feed material up to ~200°C intermittently.

6. ESCENARIOS DE APLICACIÓN

Planta siderúrgica integrada: preparación de alimentación para altos hornos

Desafío: A major steel producer experienced rapid blinding of woven wire screens during humid conditions at their BF coke bunker station. This caused significant nut coke fraction carryover into blast furnace feed bins (~12%), disrupting burden permeability and increasing fuel rate.
Solución: Implementation of two largecapacity linear motion screens fitted with nonblinding rod deck media on the upper decks for scalping oversize and openprofile polyurethane panels on lower decks for precise nut/breeze separation.
Resultados: Screening efficiency stabilized above 96%. Carryover was reduced to <3%. The plant reported an annual reduction in fuel rate attributed partly to improved burden control alongside a 65% drop in monthly screenrelated downtime.

Coke Plant – ByProduct Recovery Circuit

Desafío: A standalone coking plant needed to maximize recovery of saleable “nut” coke from its crushing circuit but struggled with excessive generation of undersize “breeze” due to aggressive screening action degrading fragile pieces.
Solución:: Installation of a threedeck unit featuring adjustable stroke length via external counterweights on its vibrator motors was selected. This allowed operators finetune intensity based on feed characteristics..
Resultados: By optimizing stroke,,the plant increased yield within target nut size range (+8%) while reducing undersize generation (15%). The gentler handling also extended lowerdeck panel life by approximately 30%.

7 CONSIDERACIONES COMERCIALES

Niveles de precios
• Standard Duty Units: For cooledcoke applications with moderate tonnage (<1000 TPH). Offers core reliability features at an entry point..
• HeavyDuty / Hot Material Units: Includes full abrasion/heat packages,,upgraded drives,,and isolation systems.. Priced approximately 2540% above standard duty..
• Custom HighCapacity Units: Engineered solutions exceeding 2000 TPH capacity often require projectspecific pricing based detailed engineering study..

Características opcionales
• Enclosed Dust Housing: With flanged connections..
• Various Chute Configurations: Including wearlined,,insulated,,or heated designs..
• Vibration Monitoring System: With sensors providing realtime data predictive maintenance schedules..
• Variable Frequency Drive Control: For precise adjustment material travel speed..

Paquetes de servicios
• Commissioning Supervision
• Annual Inspection Contracts
• Critical Spares Kits
• Onsite Training Operators Maintenance Staff

Opciones de financiación
Capital equipment financing,,operating leases available through partners terms ranging 24 84 months subject credit approval..

8 Preguntas frecuentes

Q1 How do I determine correct size model my application?
A Selection requires analysis total feed tonnage particle size distribution desired products moisture content We provide detailed questionnaire our engineers use recommend specific model configuration

Q2 Can existing foundation be used replacement unit?
A Possibly Our team requires drawings existing structure load data new unit We design adapter frames facilitate retrofits minimizing civil work costs

Q3 What typical lead time delivery?
A For standard models within catalog lead time ranges 16 weeks exworks Custom highcapacity units require longer engineering manufacturing schedule

P4 ¿Están disponibles los repuestos??
A Yes We maintain global inventory critical wearing parts including vibrator assemblies deck panels isolation elements Standard parts shipped within hours emergency orders

Q5 ¿Ofrecen garantías de rendimiento??
A Yes We guarantee mechanical performance throughput capacity screening efficiency based agreedupon test protocols provided feed specifications met

Q6 How handle installation commissioning?
A We provide comprehensive installation manuals foundation drawings supervision available optional extra ensure correct setup initial operation

Q7 What expected operational lifespan main structure?
A With proper maintenance isolation our screens designed minimum years service before major structural overhaul required Field data supports this timeline numerous installations