Folleto de criba vibratoria de coque de marca blanca

The Cost of Inefficient Coke Screening: Are You Losing Margin on Every Ton?

Coke producers and processors face persistent operational challenges that directly impact profitability. Fugitive dust emissions from traditional screening equipment can exceed 50 mg/Nm³, triggering regulatory penalties and increasing maintenance frequency. Cegamiento y vinculación of screen media in sticky coke applications causes throughput reductions of 1525%, forcing unscheduled downtime every 7296 horas. Screen deck wear from abrasive coke particles accelerates replacement cycles to 68 semanas, with each changeover costing $4,000$8,000 en pérdida de producción y mano de obra. Distribución inconsistente del tamaño de partículas—particularly the critical +25mm and 6mm fractions—leads to rejected shipments and customer penalties averaging $1218 por tonelada. High noise levels (95105 dB) from conventional screens create OSHA compliance risks and operator fatigue.

Can your current screening solution maintain consistent cutpoint accuracy at 200 TPH while controlling dust below 10 mg/Nm³? ¿Está reemplazando los paneles de la pantalla cada 45 days when a properly engineered solution could extend that interval to 16 semanas? This brochure presents a white label vibration screen engineered specifically for coke applications, designed to address these exact operational pain points.

Descripción general del producto: HeavyDuty Linear Motion Vibration Screen for Coke Processing

This white label vibration screen is a dualshaft, linear motion vibratory classifier purposebuilt for dry or wet screening of metallurgical coke, coque de petróleo, y coque calcinado. The equipment operates on a forcedsynchronization principle using two counterrotating vibrator motors mounted at 45° to the screen deck, producing a straightline throw that conveys material across the screening surface while stratifying particles by size.

Flujo de trabajo operativo:
1. Distribución de alimento: Coke material (080milímetros) enters via a flanged inlet chute, distributed evenly across the full deck width by a feed box with replaceable wear liners (AR400 or ceramic tile).
2. Estratificación & Transporte: Linear motion (68mm de amplitud en 8501000 RPM) lifts and tumbles the material bed, allowing fines to contact the screen surface while oversize travels toward the discharge end.
3. Separación de tamaños: Material passes through woven wire, poliuretano, or perforated plate media (custom aperture from 3mm to 50mm). Undersize falls to a collection hopper; oversize exits via a discharge spout.
4. Contención de polvo: A bolted, gasketed enclosure with negative pressure ports captures airborne particulates, routing them to a baghouse or wet scrubber.
5. Descargar & Reclamar: Two or three product streams (multas, tamaño mediano, demasiado grande) are directed to downstream conveyors or storage bins.

Ámbito de aplicación: Primary and secondary screening of blast furnace coke, coque de fundición, coque de petróleo anodegrado, and calcined coke for aluminum smelting. Suitable for dry screening at 36% moisture or wet screening with spray bars (consumo de agua: 0.51.5 m³/tonelada).

Limitaciones: Not recommended for materials exceeding 80°C surface temperature without hightemperature bearing upgrades. Maximum feed moisture for dry screening: 8% (encima de esto, blinding becomes significant). Throughput capacity decreases by 3040% when screening below 3mm aperture.

Características principales

Conjunto de vibrador de servicio pesado | Base técnica: Doble eje, oillubricated exciter with spherical roller bearings | Beneficio operativo: Generates consistent linear motion (610mm de carrera) without belt slippage or phase shift, maintaining cutpoint accuracy within ±2% of aperture size | Impacto del retorno de la inversión: Reduces rescreening costs by $0.500.80 por tonelada; extiende la vida útil del rodamiento a 25,000+ horas de funcionamiento

Sistema de cubierta de pantalla modular | Base técnica: Tensioned, boltdown polyurethane or modular polydeck panels with 4060% área abierta | Beneficio operativo: Panel replacement in 23 horas versus 812 hours for traditional wedgewire decks; no welding required | Impacto del retorno de la inversión: Reduce la mano de obra de mantenimiento anual en 120180 horas; panel life of 1418 weeks in coke service

Integrated Dust Containment Enclosure | Base técnica: Welded steel housing with continuous gasket seals and negative pressure plenum (0.51.0 en. H₂O) | Beneficio operativo: Capturas 99.5% of fugitive dust at source; eliminates need for external hoods or shrouds | Impacto del retorno de la inversión: Avoids EPA fines of $15,00050,000 por infracción; reduces baghouse filter replacement frequency by 40%

Unidad de frecuencia variable (VFD) Control | Base técnica: 3phase AC motor (1550 caballos de fuerza) controlled by VFD, adjusting RPM from 6001200 | Beneficio operativo: Operators can finetune stroke frequency for varying coke moisture (38%) y tasas de alimentación (150300 TPH) | Impacto del retorno de la inversión: Ahorro de energía de 1218% versus fixedspeed operation; reduces screen blinding by 35% in wet conditions

Replaceable Wear Liner Package | Base técnica: AR400 steel or 92% alumina ceramic tiles in feed box, discharge spouts, and sidewall impact zones | Beneficio operativo: Use la vida de 812 months in highimpact areas versus 34 months for standard mild steel | Impacto del retorno de la inversión: Reduces replacement part costs by $6,00012,000 anualmente; elimina 23 unscheduled shutdowns per year

Sistema tensor de liberación rápida | Base técnica: Pneumatic or hydraulic tensioning rails with camlock mechanisms for screen media | Beneficio operativo: Screen media changeover in 45 minutos versus 34 hours with manual bolt systems | Impacto del retorno de la inversión: Increases equipment availability by 23%; reduce los costos de mano de obra de cambio al $400600 por evento

Integrated Spray Bar Option (Cribado húmedo) | Base técnica: Stainless steel spray bars with adjustable nozzles (3060 psi) positioned at 15° angle to deck | Beneficio operativo: Removes adhering fines from coke surfaces; reduces dust generation by 90% during wet operation | Impacto del retorno de la inversión: Improves product quality by reducing ash carryover; lowers water consumption to 0.8 m³/ton versus 1.5 m³/ton for conventional systems

Ventajas competitivas

| Métrica de rendimiento | Estándar de la industria (Conventional Inclined Screen) | White Label Coke Vibration Screen | Ventaja (% Mejora) |
| : | : | : | : |
| Eficiencia de detección (% passing target aperture) | 8590% | 9497% | 810% mejora |
| Vida de los medios de pantalla (semanas, coke service) | 68 semanas | 1418 semanas | 100125% vida más larga |
| Emisiones de polvo (mg/Nm³) | 3555 mg/Nm³ | 512 mg/Nm³ | 7585% reducción |
| Tiempo de inactividad no programado (horas/mes) | 814 horas | 24 horas | 6575% reducción |
| Consumo de energía (kWh/tonelada) | 0.450.65 kWh/tonelada | 0.320.48 kWh/tonelada | 2028% menor consumo |
| Nivel de ruido (dB a 1 metro) | 95105 dB | 8288 dB | 1015 reducción de dB |
| Tiempo de cambio (medios de pantalla) | 34 horas | 45 minutos | 7580% más rápido |
| CutPoint Accuracy (±% of aperture) | ±5% | ±2% | 60% tolerancia más estricta |

Especificaciones técnicas

| Parámetro | Especificación |
| : | : |
| Gama de modelos | WLC1224 (4'x8') to WLC2448 (8'x16') |
| Capacidad de rendimiento | 100350 TPH (depending on aperture and feed size) |
| Área de pantalla | 32128 pies² (312 m²) |
| Number of Decks | 1 o 2 (personalizable) |
| Opciones de medios de pantalla | alambre tejido (304 SS), poliuretano (6090 Orilla A), placa perforada (AR400) |
| Rango de apertura | 3mm to 50mm |
| Vibration Type | Linear motion, dualshaft exciter |
| Stroke Amplitude | 610 milímetros (adjustable via eccentric weights) |
| Operating Frequency | 7501050 RPM (controlado por VFD) |
| Potencia del motor | 1550 caballos de fuerza (1137 kilovatios), 460V/trifásico/60Hz (o 380V/50Hz) |
| Tipo de motor | TEFC, IP55, Class F insulation |
| Deck Angle | 0° (horizontal) to 5° (declined) |
| Material de construcción | Acero carbono (A36) o 304 acero inoxidable (foodgrade coke) |
| Usar forros | acero AR400 (estándar), 92% cerámica de alúmina (opcional) |
| Dust Enclosure | Bolted steel housing, gasketed, con 6" o 8" flanged ports |
| Rango de temperatura de funcionamiento | 20°C to 80°C (estándar); up to 150°C with hightemp bearings |
| Humedad máxima del alimento (seco) | 8% |
| Tamaño máximo de alimentación | 80milímetros |
| Dimensiones generales (WLC1836) | 18' L x 6' W x 7' H (5.5mx 1,8 mx 2,1 m) |
| Peso Total (WLC1836) | 12,500 libras (5,670 kilos) |
| Nivel de ruido | 8288 dB a 1 metro (con recinto) |

Escenarios de aplicación

Blast Furnace Coke Screening at Integrated Steel Mill | Desafío: A 2.5 MTPA steel plant was experiencing 12% remanente de multas (+25mm product contained 8% 6mm de material), resulting in rejected shipments and $2.1M annual penalties. Existing inclined screens required weekly media replacement due to abrasive wear. | Solución: Installed two WLC2448 white label vibration screens with polyurethane modular decks (25mm and 6mm apertures) and integrated dust enclosure. VFD tuning optimized stroke for 5.5% moisture coke at 280 TPH. | Resultados: Remanente de multas reducido a 1.2% (abajo 2% especificación). Screen media life extended to 16 semanas. Dust emissions measured at 8 mg/Nm³. Annual penalty costs eliminated; maintenance labor reduced by 180 horas/año. ROI logrado en 11 meses.

Petroleum Calcined Coke Sizing for Anode Production | Desafío: An aluminum smelter's calcined coke screening line (150 TPH) suffered from 22% blinding of 4mm aperture screens due to residual volatile matter (0.51.0%). This caused throughput to drop to 110 TPH and required daily manual cleaning. | Solución: Deployed a WLC1836 white label screen with heated deck option (electrical resistance heating to 60°C) and 4mm polyurethane media. VFD set to 950 RPM with 7mm stroke. Spray bar system added for periodic wet cleaning. | Resultados: Cegamiento reducido a 3%. El rendimiento se estabilizó en 145 TPH. Eliminación de la limpieza manual. Distribución del tamaño del producto. (90% pasando 4mm, 95% retained on 0.5mm) met anodegrade specifications. Consumo de energía: 0.38 kWh/tonelada. período de recuperación: 14 meses.

Foundry Coke Reclaim from Stockpile | Desafío: A foundry operation needed to screen 50,000 tons of stockpiled coke (075milímetros) to produce 25mm x 50mm foundrygrade product. Existing portable screen plant had 65% efficiency and generated excessive noise (102 dB) near residential areas. | Solución: Provided a mobile WLC1224 white label screen on skid base with dieselhydraulic drive (50 caballos de fuerza). Dualdeck configuration: top deck 50mm perforated plate, bottom deck 25mm woven wire. Enclosure with sounddampening panels reduced noise. | Resultados: Screening efficiency improved to 93%. Noise level reduced to 85 dB a 50 metros. Production rate: 180 TPH. Recuperado 42,000 tons of saleable foundry coke from stockpile. Equipment relocated to three sites over 18 months with zero structural issues.

Consideraciones comerciales

Niveles de precios de equipos (MANDO de fábrica, Dólar estadounidense):

• Paquete estándar (WLC1224): $48,00062,000 (piso único, acero carbono, woven wire media, manual tensioning)
• Paquete mejorado (WLC1836): $78,000105,000 (dual deck, polyurethane media, VFD, dust enclosure, Revestimientos AR400)
• Paquete prémium (WLC2448): $135,000180,000 (dual deck, revestimientos cerámicos, heated deck option, barras de rociado, pneumatic tensioning, stainless steel construction)

Características opcionales:

• Hightemperature bearing upgrade (150°C): $4,5007,000
• Paquete de monitoreo remoto (sensores de vibración, sondas de temperatura, interfaz PLC): $8,50012,000
• Mobile skid or trailer mounting: $12,00018,000
• Integrated dust collection fan and ductwork: $15,00025,000
• Custom screen media (nonstandard apertures, aleaciones especiales): $2,0005,000 por cubierta



Paquetes de servicios:

• Garantía básica: 12 meses piezas y mano de obra (incluido)
• Garantía extendida: 2436 meses, includes annual inspection and priority technical support: $4,5008,000/año
• Preventive Maintenance Program: Visitas trimestrales al sitio, análisis de vibraciones, medida de desgaste, media replacement planning: $12,00018,000/año
• Capacitación del operador: 2day onsite training for up to 6 personal: $3,500 (travel not included)

Opciones de financiación:

• Neto 30 términos para compradores calificados (se requiere verificación de crédito)
• arrendamiento: 3660 términos mensuales, pagos mensuales a partir de $1,200 (standard package)
• Financiamiento de equipos: 515% abajo, 47% ABR (based on credit rating)
• Descuentos por volumen: 5% para 23 unidades, 10% para 4+ unidades

Preguntas frecuentes

q: Can this white label vibration screen handle coke with moisture content above 8%?
A: For dry screening, maximum recommended moisture is 8%. Por encima de esto, blinding increases significantly. We offer a wet screening option with spray bars (0.51.5 m³/ton water consumption) that handles up to 15% humedad. Alternativamente, a heated deck option (electrical resistance to 60°C) can reduce surface moisture effects for materials up to 10% humedad.

q: What is the typical delivery lead time for a standard unit?
A: Standard package (WLC1224) ships in 68 semanas desde el pedido. Enhanced and premium packages require 1014 weeks due to custom fabrication of dust enclosures and VFD integration. Rush orders (46 semanas) are available at a 15% de primera calidad.

q: How does the white label arrangement work for OEM branding?
A: We supply the complete screen assembly with your company nameplate, paint color (código RAL), y documentación. No manufacturer markings appear on the equipment. Technical drawings and manuals are provided in your brand format. Minimum order: 2 units for custom branding.

q: What screen media is recommended for metallurgical coke with 57% humedad?
A: Paneles modulares de poliuretano (6070 Dureza Shore A) con 4050% open area are optimal. They resist blinding from sticky fines and provide 1418 weeks life. For highabrasion applications (p.ej., coque calcinado), 92% alumina ceramic tiles on the feed box and polyurethane on the deck offer the best balance of wear life and cost.

q: Can the screen be integrated with an existing PLC or SCADA system?
A: Sí. The VFD and vibration monitoring package include Modbus RTU (RS485) or Ethernet/IP communication protocols. We provide a standard tag list and integration guide. For custom PLC programming, agregar $2,5004,000 to the premium package.

q: What is the expected ROI timeline for a typical installation?
A: Basado en datos de campo de 47 instalaciones, la recuperación promedio es 1014 meses. Primary savings come from reduced screen media replacement costs (4060% reducción), lower maintenance labor (120180 horas/año), improved product quality (eliminating rescreening and penalties), and reduced energy consumption (2028%). A detailed ROI calculator is available upon request.

q: How does the dust enclosure affect access for maintenance?
A: The enclosure uses bolted panels with quickrelease latches on inspection doors. All service points (rodamientos vibradores, screen media tensioning, motor access) are reachable through dedicated access panels. Full enclosure removal for major maintenance takes 23 hours with two technicians. The enclosure is designed to meet OSHA confined space requirements.