1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Are escalating operational costs and unpredictable downtime eroding your mineral processing margins? In coke handling and classification, inefficient screening directly impacts product quality, rendimiento, y presupuestos de mantenimiento. Los desafíos comunes incluyen:
Blinding & Carryover: Moisture and fines clog screen decks, reducing effective screening area and causing product contamination. This leads to rejected loads, customer chargebacks, and manual cleaning downtime.
Excessive Wear & Mantenimiento: The abrasive nature of coke rapidly degrades standard screen panels and components, resulting in frequent replacements, high spare parts inventories, and lost production hours.
Distribución inconsistente del tamaño de partículas: Unstable vibration or inadequate screening action produces offspec material, compromising downstream blast furnace efficiency or foundry coke specifications.
Alto consumo de energía & Structural Stress: Poorly balanced vibratory systems consume excess power and transmit damaging forces to the support structure, increasing both operational costs and longterm facility wear.

Is your current solution addressing these core issues? A precisionengineered Luxury Coke Vibration Screen is not merely a component; it is a strategic investment in process stability and cost control.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

El Luxury Coke Vibration Screen is a highcapacity, heavyduty linear motion vibrating screen specifically engineered for the dry screening of metallurgical coke and similar abrasive materials. Its design focuses on maximizing availability and minimizing total cost of ownership in continuous 24/7 operaciones.

Flujo de trabajo operativo:
1. Alimentación controlada: Sized coke from crushers or storage is evenly distributed across the full width of the feed inlet.
2. Efficient Stratification & Separación: A highGforce linear vibration stratifies the material bed, forcing fines downward while conveying oversize along the deck for accurate separation through precisely sized screen apertures.
3. Descargar: Correctly sized fractions are discharged into distinct chutes—oversize for recirculation, onspec product for shipment or further processing.

Ámbito de aplicación: Ideal for final sizing (p.ej., separating 2580mm blast furnace coke from fines) or scalpandgrade operations in coke plants, steel mills, and foundries.
Limitaciones: Not designed for wet screening applications or for materials with extreme stickiness without specialized deck treatments.

3. CARACTERÍSTICAS PRINCIPALES

Advanced Deck System | Base técnica: Modular polyurethane/ rubber composite panels with reinforced steel backing | Beneficio operativo: Dramatically reduces blinding; panels are easily replaced individually without full deck dismantling | Impacto del retorno de la inversión: Arriba a 40% reduction in panel changeout time; extends panel life by 60100% over standard steel

DualMass Vibrator Drive | Base técnica: Two counterrotating eccentric shafts generating a linear force | Beneficio operativo: Smooth, reliable startup under load; consistent stroke regardless of feed variations; minimal force transmission to base structure | Impacto del retorno de la inversión: Lower structural support costs; reduced bearing stress cuts maintenance frequency

HuckBolt® Frame Construction | Base técnica: Highstrength lockbolt technology replacing traditional welding at critical joints | Beneficio operativo: Eliminates stress fractures and frame fatigue failures common in welded designs under cyclic loading | Impacto del retorno de la inversión: Significantly extends structural life (often beyond 10+ años), eliminating major rebuild costs

Unidad de frecuencia variable (VFD) Control | Base técnica: Precision control of motor speed to adjust vibration amplitude/frequency | Beneficio operativo: Operators can finetune screening action for different coke grades or moisture conditions to optimize efficiency | Impacto del retorno de la inversión: Prevents overscreening energy waste; improves yield by adapting to realtime feed conditions

Centralized Lube System | Base técnica: Automated greasing lines feeding all vibrator bearing points | Beneficio operativo: Ensures optimal bearing lubrication without manual intervention during operation | Impacto del retorno de la inversión: Extends critical bearing life by up to 30%, preventing catastrophic failure and unplanned stoppages

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria | Luxury Coke Vibration Screen Solution | Ventaja (% mejora) |
| : | : | : | : |
| Screen Availability (tiempo de actividad) | 9092% typical between planned maintenance events. Field data shows consistent >96% availability due to robust construction & reduced unscheduled stops. +57% mejora |
| Panel Replacement Labor Hours Requires full crew & shift downtime for section replacement. Modular system allows singleworker panel swaps during short scheduled pauses 60% labor time |
| Energy Consumption per Ton kW/ton processed can vary with load imbalance Fixed optimized stroke with VFD optimization reduces peak demand 1520% typical consumption |
| Consistencia del producto (PSD Accuracy) Manual adjustment often leads to variance in cut point Automated tuning via VFD maintains precise cut point under variable feed +12% consistency in target fraction yield |

5. ESPECIFICACIONES TÉCNICAS

Capacidad/clasificación: Modelos de 50 TPH a 1,200 TPH capacity for coke sizing (dependent on aperture size and moisture content).
Requisitos de energía: Drive motors from 7.5 kW a 45 kW per vibrator unit (typically dualdrive), compatible with 400V/50Hz or other industrial standards.
Especificaciones de materiales: Deck frames constructed from abrasionresistant steel (AR400 liners at feed points). Side plates are hightensile steel. Options include stainless steel contact parts for corrosive environments.
Dimensiones físicas: Singledeck widths from 1.2m to 3.6m; lengths from 4.8m to 9m customconfigured.
Rango de operación ambiental: Diseñado para temperaturas ambiente de 20°C a +50°C. Dusttight enclosures available for indoor installations requiring emission control.

6. ESCENARIOS DE APLICACIÓN

Integrated Steel Plant Blast Furnace Feed Challenge: Offspec fines (98% purity of +25mm fraction Reduced BF fuel rate by ~1.5% Payback period under 14 months via fuel savings

Merchant Coke Producer Challenge High customer rejections due to excessive carryover of fines into lump product shipments leading to financial penalties Solution Retrofitted existing screens with the Advanced Deck System polyurethane panels Results Near elimination of blinding incidents Carryover reduced from ~8% to <2% Customer chargebacks eliminated within first quarter

Foundry Coke Processing Challenge Frequent structural weld failures on existing screens causing unplanned weekly downtime Solution Replacement with HuckBolt frame constructed Luxury model Results Zero structural failures recorded in first two years of operation Maintenance schedule shifted entirely to predictable quarterly inspections

7 CONSIDERACIONES COMERCIALES

Equipment pricing is tiered based on size capacity robustness level:
Tier I Standard Duty Units For lower tonnage (800TPH) or specific space/seismic constraints

Optional Features Include dust encapsulation covers heated decks for highhumidity climates specialized screen cloths ceramic wear liners

Paquetes de servicios disponibles:
1 Basic Warranty covering parts/labor
2 Extended Service Plan including annual inspections vibration analysis
3 Full Lifecycle Contract guaranteeing availability with fixed annual cost covering all parts preventive predictive maintenance

Financing Options Capital lease operating lease or loan structures can be arranged often aligning payment schedules with projected efficiency savings

8 Preguntas frecuentes

Q What existing infrastructure is required?
A The screen requires a prepared concrete foundation rated for dynamic loads electrical supply at motor specs feed/discharge chute interfaces Our engineering package provides all interface drawings

Q How disruptive is installation?
A For greenfield projects we integrate into your build timeline For retrofit we design preassembled modules minimize downtime typically requiring a scheduled outage

Q Can this screen handle other materials?
A While optimized for dry coke the fundamental design is suitable for other abrasive minerals like sinter iron ore pellets Specific deck configurations may be advised

Q What is the expected operational lifespan?
A With proper maintenance key structural components are designed fora minimumofyears Critical wear items like decks/bearings have defined lifespans outlinedin themanual basedon operating hours

Q Are performance guarantees provided?
A Yes We provide guaranteed capacity throughput based on agreed feed specificationsand guaranteed product sizing accuracyunder defined conditions Theseare formalizedin the commercial contract