1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Is your coke handling operation losing profitability to inefficient screening? Common challenges with conventional screens directly impact your bottom line. ¿Estás experimentando:
Excessive Product Loss: Fines and valuable coke breeze passing through worn or inefficient screen decks, Representa una pérdida directa de ingresos por cada tonelada procesada..
Alto tiempo de inactividad por mantenimiento: Frequent failures of screen decks, aspectos, or exciters due to the extreme abrasion and impact of coke, leading to unscheduled stoppages and production delays.
Cegador & Poor Efficiency: Moisture or sticky fines blinding screen meshes, reduciendo drásticamente el área de detección efectiva y el rendimiento, forcing recirculation and increasing energy costs.
Clasificación de productos inconsistente: Unreliable particle size separation resulting in offspec product for blast furnace or foundry customers, risking contract penalties and reputational damage.
Preocupaciones por la integridad estructural: Constant, highimpact vibration leading to fatigue cracks in the screen body or support structure, creating major safety risks and costly capital repairs.

La pregunta central para los gerentes de planta es: ¿Cómo se puede lograr precisión?, reliable coke classification while maximizing uptime and protecting your material yield?

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

The Export Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the dry classification of metallurgical coke and coke breeze. Designed for robustness in harsh environments, it separates crushed coke into precise size fractions critical for blast furnace efficiency and other industrial processes.

Flujo de trabajo operativo:
1. Introducción al feed: Sized coke from crushers is evenly distributed onto the feed box of the vibrating screen.
2. Estratificación & Separación: Alta intensidad, linear or circular vibration stratifies the material bed. Smaller particles descend to contact the screen cloth apertures, mientras que las partículas más grandes viajan por la superficie de la plataforma.
3. Descarga de fracción de tamaño: Correctly sized particles pass through the screen mesh (tamaño insuficiente), while oversized particles discharge at the deck end (demasiado grande). Multideck configurations allow for simultaneous separation into several product grades.

Ámbito de aplicación: Cribado primario y secundario de coque metalúrgico., recuperación de brisa de coque, sizing for sinter plants, and prescreening for gasification processes.

Limitaciones: Not designed for wet screening applications or for materials with extreme adhesive properties without specialized deck treatments.

3. CARACTERÍSTICAS PRINCIPALES

Sistema de cubierta modular | Base técnica: las bolas, subframe mounted polyurethane or rubber clad steel panels | Beneficio operativo: Dramatically reduced replacement time; individual panels can be changed without full deck dismantling. | Impacto del retorno de la inversión: Reduce el tiempo de inactividad por mantenimiento planificado hasta en 60%, aumento de horas de funcionamiento anuales.

HeavyDuty Exciter Assembly | Base técnica: Internally mounted, greaselubricated vibrator unit with oversized bearings and labyrinth seals | Beneficio operativo: Isolated from direct material impact; delivers consistent amplitude under variable load conditions. | Impacto del retorno de la inversión: Proven service intervals exceeding 8,000 hours under continuous operation, reducing spare part consumption.

HuckBolted Construction | Base técnica: Highshear strength fastener system used throughout the main frame and side plates | Beneficio operativo: Eliminates weld fatigue failures; creates a rigid, maintenancefree body structure resistant to crack propagation. | Impacto del retorno de la inversión: Extiende la vida útil estructural por años, evitando costos prematuros de reposición de capital.

Tiered Dust Enclosure | Base técnica: Multisegment rubber skirtboard system with quickrelease clamps at multiple transfer points | Beneficio operativo: Contains dust emission at feed, descargar, and side skirts; improves plant environmental compliance. | Impacto del retorno de la inversión: Mitigates material loss as airborne fines and reduces housekeeping labor requirements.

Suspensión de resorte sintonizada | Base técnica: Computermodeled coil spring or rubber buffer system matched to dynamic load parameters | Beneficio operativo: Aísla hasta 85% de fuerzas dinámicas de la estructura de soporte; allows installation on elevated platforms. | Impacto del retorno de la inversión: Eliminates costly structural reinforcement needs during installation and minimizes vibration transmission.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (Pantallas convencionales) | Export Coke Vibration Screen Solution | Ventaja (% mejora) |
| : | : | : | : |
| Vida útil del panel de cubierta| 36 months with steel wire mesh | 1218 months with polyurethane clad panels | +150% mejora promedio |
| Disponibilidad Anual| ~8590% (incluyendo paradas planificadas)| >94% (documented field data) |>4 percentage point gain |
| Eficiencia de detección| 8590% on dry 6mm separation| Consecuentemente >94% on same duty| +5% reduction in misplaced fines |
| Consumo de energía por tonelada| Base (100%)| Unidad optimizada & El balance de masa reduce el consumo en ~15%.| 15% menor costo operativo |
| Instalación & Tiempo de puesta en servicio| 57 days for full assembly on site| Preassembled modules reduce field work to 23 días|<50% of standard time |

5. ESPECIFICACIONES TÉCNICAS

Capacidad / Clasificación: Depende del modelo; rango de 500 MTPH a 2,500 MTPH de coque seco (bulk density ~0.50.6 t/m³).
Requisitos de energía: Impulsar motores de 15 kW a 45 kW por unidad vibradora (típicamente doble unidad), 400/690V y, IP66 protection standard.
Especificaciones de materiales:
Marcos de cubierta & Placas laterales: Acero resistente a la abrasión (AR400/450).
Cubiertas de pantalla: Modular polyurethane panels with embedded steel reinforcement; optional rubberclad steel or tensioned wire cloth.
Marco principal & Miembros cruzados: Heavywalled structural steel with corrosioninhibiting primer.
Dimensiones físicas: Singledeck widths from 1.8m to 3.6m; longitudes de 4,8 ma 7,2 m.
Rango de operación ambiental: Temperatura ambiente de 20°C a +45°C; designed for outdoor installation with appropriate electrical components.

6. ESCENARIOS DE APLICACIÓN

Integrated Steel Plant Blast Furnace Feed

Challenge A major steel producer faced consistent fines (5milímetros) contamination in their BFgrade coke (2575milímetros), affecting furnace permeability and increasing coke rate.
Solution Installation of a primary Export Coke Vibration Screen with two decks following secondary crushing.
Results Achieved a clean +25mm product with less than 3% undersize contamination while recovering 5mm breeze for sinter plant use—a quantifiable reduction of $12/ton in effective BF feed cost.

Productor comercial de coque

Challenge Offspec product batches due to inconsistent screening after rain events caused moistureinduced blinding on traditional screens.
Solution Implementation of our screens equipped with specialized antiblinding polyurethane decks featuring slotted apertures and balltray cleaning systems.
Results Screening efficiency remained above 92% even with surface moisture up to 7%, eliminating penalty clauses related to product sizing in supply contracts within one quarter.

7 CONSIDERACIONES COMERCIALES

Export Coke Vibration Screens are offered in three primary tiers:

1. Serie de servicio estándar: Para capacidades de hasta ~800 MTPH. Includes core heavyduty construction features ideal for most merchant coke operations.
2. Serie de servicio pesado: For capacities from ~800 MTPH to ~1,800 MTPH featuring enhanced exciter specifications and premiumtier bearing assemblies—the recommended choice for integrated steel plants.
3. Serie de servicio extra pesado: For ultrahighcapacity applications exceeding ~1，800 MTPH， incorporating duplex bearing exciters， diseño de marco reforzado，and premium dust sealing packages．

Optional features include stainless steel fasteners，full stainless steel skirting，integrated spray systems for limited dust suppression，and condition monitoring sensor ports．

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including scheduled inspections，análisis de vibraciones，and guaranteed spare parts availability．Financing options including equipment leasing are available through accredited partners．

Preguntas frecuentes

Q What is the lead time for a typical Export Coke Vibration Screen?
A Lead times vary by model complexity．For standard configurations，expect delivery within X weeks upon order confirmation．Customized solutions may require additional engineering time．

Q Can this equipment integrate into our existing PLCcontrolled plant？
A Yes．All drives are compatible with standard industrial motor starters．The screen itself is supplied readyforsignal connection；it does not include complex control logic but can interface with your plant’s start/stop interlocks．

Q How does this design handle variations in feed rate？
A The exciter system generates a constant force independent of load．While efficiency is optimized at design capacity，field data shows performance degradation remains minimal (±2%) within a ±20% feed rate fluctuation．

Q What are the primary wear items？
A The primary consumables are the modular deck panels followed by wear liners on feed boxes．Spare parts kits based on recommended annual usage are available．

Q Do you provide installation supervision？
A Yes．Professional commissioning supervision is offered as an optional service package．This includes final alignment checks，initial startup assistance，and operator training．

Q Are your technical specifications guaranteed？
A All performance figures stated are based on standard test conditions using defined material characteristics．We provide written performance guarantees as part of our commercial proposal based on your specific application data sheet．

Q What financing structures do you offer？
A We work with thirdparty financial institutions that offer operating leases，capital leases/finance leases,and traditional purchase loans.Structures can be tailored over terms typically ranging from X years