1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Is your coke handling and classification process a source of constant operational friction? For plant managers overseeing coke production for metallurgical or foundry applications, standard screening solutions often fall short, leading to persistent challenges that directly impact your bottom line.

Aveuglant & Reporter: Are you experiencing frequent screen cloth blinding from moist, sticky coke fines, forcing premature shutdowns for manual cleaning and causing significant product carryover into the wrong fractions?
Excessive Maintenance & Temps d'arrêt: Does the abrasive nature of metallurgical coke lead to rapid wear on screen components, generating high replacement part costs and unplanned maintenance cycles that disrupt your entire production line?
Inefficient Separation & Contamination du produit: Are you struggling to achieve clean, precise cuts between coke sizes? Inefficient separation results in offspec product—either oversized material contaminating the nut coke fraction or excessive fines where lump is required—compromising quality and value.
Fatigue structurelle & Transmission des vibrations: Do conventional screens transfer excessive dynamic loads to your support structure, leading to longterm fatigue cracks, safety concerns, and costly structural reinforcements?

What if a screening solution was engineered from the ground up to address the specific material characteristics of coke? A system designed not just to separate, but to enhance overall circuit reliability and product integrity.

2. APERÇU DU PRODUIT: BESPOKE COKE VIBRATION SCREEN

The Bespoke Coke Vibration Screen is a heavyduty, highcapacity screening machine specifically engineered for the dry classification of metallurgical, foundry, et coke de pétrole. It is not an adapted generic screen; it is purposebuilt for the unique abrasiveness, densité, and granulometry of coke products.

Flux de travail opérationnel:
1. Alimentation contrôlée: Coke feedstock is delivered onto the screen via an integrated feed box or chute, ensuring even distribution across the full width of the top deck to maximize screening surface utilization.
2. Stratification à haute intensité: A precisely tuned dualvibration mechanism (linear or elliptical, as specified) aggressively stratifies the material bed. This forces finer particles down to the screen cloth while conveying larger pieces toward the discharge end.
3. Precision Separation: Sized fractions pass through designated deck apertures (typically multiple decks for 34 product splits), with antiblinding devices ensuring apertures remain clear for consistent accuracy.
4. Décharge & Transport: Cleanly separated fractions (par ex., du coca en morceaux, coca aux noix, brise) are discharged via dedicated outlets into chutes or onto conveyor belts for downstream processing or storage.

Champ d'application: Calibrage primaire et secondaire du coke métallurgique (haut fourneau), coke de fonderie, anodegrade petroleum coke, and calcined coke. Ideal for greenfield installations or as a direct replacement for underperforming units in existing crushing circuits.

Limites: Non conçu pour les applications de criblage humide ou pour les matériaux soumis à des températures extrêmes (>200°C) sans modifications particulières. Maximum feed size is limited by physical deck dimensions and impact resistance specifications.

3. CARACTÉRISTIQUES PRINCIPALES

Système de pont anti-aveuglement | Base technique: Polyurethane tensioned panels with integrated ball trays or flexible urethane cleaners | Avantage opérationnel: Continuous micromovements prevent fine particles from lodging in screen apertures | Impact sur le retour sur investissement: Reduces downtime for cleaning by up to 70%, maintaining consistent throughput and product spec.

Construction de cadre robuste | Base technique: Reinforced boxsection steel with internal crossbracing and stressrelieved welds | Avantage opérationnel: Absorbe les charges dynamiques, minimizing vibration transmission to supporting structures | Impact sur le retour sur investissement: Eliminates costs associated with structural reinforcement and reduces longterm infrastructure fatigue failures.

Tiered Vibration Mechanism | Base technique: Ruggedized vibrator assemblies (unbalanced shaft or exciter drives) with oversized bearings and labyrinth seals | Avantage opérationnel: Delivers reliable, highGforce vibration in dusty environments with minimal maintenance intervention | Impact sur le retour sur investissement: Extends bearing service life by 23x versus standard screens, réduire les stocks de pièces et les coûts de main-d'œuvre.

Ensemble de doublure résistante à l'abrasion | Base technique: Bolton wear liners made of AR400 steel or replaceable polyurethane on all critical contact points (boîte d'alimentation, plaques latérales) | Avantage opérationnel: Protects structural components from direct abrasive wear | Impact sur le retour sur investissement: Dramatically reduces replacement frequency of major frame components; only inexpensive liners require periodic changeout.

Dust Containment Design | Base technique: Integrated dust skirt flanges and sealed inspection covers at multiple access points | Avantage opérationnel: Contient de la poussière de coke en suspension dans l'air aux points de transfert, improving site environmental conditions and safety | Impact sur le retour sur investissement: Reduces housekeeping labor and mitigates risk of combustible dust accumulation.

Modular Deck Configuration | Base technique: Independently tensioned screen decks with quickchange clamping systems support wire mesh, polyuréthane, or rubber panels | Avantage opérationnel: Enables rapid panel changeover (<4 heures) and flexible adaptation to changing product size specifications | Impact sur le retour sur investissement: Cuts maintenance downtime by over 50% during screen media replacement.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Industry Standard Screen | Bespoke Coke Vibration Screen Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité / Temps de disponibilité| 8590%, frequent stops for deblinding & ajustements| >96%, sustained operation between planned maintenance| +7% à +12% more productive runtime |
| La vie des médias à l'écran| Standard wire cloth lasts 68 weeks in abrasive service| Specialized urethane/compound panels last 1420 semaines| +100% à +150% durée de vie plus longue |
| Efficacité de séparation| ~8590% efficiency on difficult <10mm separations| Réalise systématiquement 9295% efficiency on same cut point| +5% à +8% more saleable onspec product |
| Coût d'entretien annuel| Haut; frequent bearing changes & structural repairs| Faible; sealedforlife vibrators & protected structure| Jusqu'à 40% reduction in annual parts/labor spend |

5. SPÉCIFICATIONS TECHNIQUES

Gamme de modèles & Capacité: Sizes from 1.2m x 3.0m (single deck) up to 2.4m x 6.0m (triple deck). Capacités de 50 TPH jusqu'à 800 TPH depending on aperture size and product gradation.
Exigences d'alimentation: Drive motor power range from 7.5 kW à 45 kW par unité de vibrateur (généralement à double disque), supplied at 400/690V AC.
Spécifications matérielles: Cadre principal: Acier de construction S355JR. Surfaces d'usure: AR400 steel or modular polyurethane liners. Plateformes d'écran: Hightensile steel side plates with tensioning system compatible with all major panel types.
Dimensions physiques & Poids: Varie selon le modèle; example model BCVS1836 (1.8m x 3.6m): ~6500kg footprint of ~2.2m W x ~4.5m L x ~2m H (excluding feed/discharge height).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C. Enclosure rating standard IP65 for electrical components.

6. SCÉNARIOS D'APPLICATION

Usine de préparation de coke de haut fourneau

Challenge A major steel producer faced persistent blinding on finalstage nut coke screens (<30mm), causing hourly downtime for rodding and significant carryover of fines into blast furnace feedstock.
Solution Replacement with a Bespoke Coke Vibration Screen featuring a tiered antiblinding deck system tailored for highmoisture conditions.
Results Screening efficiency improved from 82% à 94%. Unplanned stoppages were eliminated within that circuit segment Annual output increased by an estimated ~15kt due to sustained throughput

Producteur de Coca-Cola de Fonderie

Challenge Excessive vibration from aging screens was causing cracks in the supporting mezzanine structure creating safety hazards The producer also needed more precise separation between lump (>80mm) hearth grades
Solution Installation of two heavy duty frames designed with internal damping along with customised elliptical stroke vibrators
Results Measured vibration transmitted load reduced by Measured vibration transmitted load reduced by Structural integrity concerns were resolved allowing simultaneous upgrade achieved cleaner hearth grade product reducing recirculation load

Usine de coke de pétrole calciné

Challenge Extreme abrasiveness of calcined CPC was wearing out standard screen components every month leading volatile maintenance schedules high inventory costs
Solution Implementation featuring full AR lining package tiered vibrators equipped ceramic labyrinth seals
Results Wear liner replacement extended cycle months Major frame component life projected exceed years Bearing changeout interval extended months

Usine de coke de pétrole calciné

Challenge The extreme abrasiveness of calcined CPC was wearing out standard screen components every month leading volatile maintenance schedules high inventory costs
Solution Implementation featuring full AR lining package tiered vibrators equipped ceramic labyrinth seals
Results Wear liner replacement extended cycle months Major frame component life projected exceed years Bearing changeout interval extended months

Usine de coke de pétrole calciné

Challenge The extreme abrasiveness of calcined CPC was wearing out standard screen components every month leading volatile maintenance schedules high inventory costs
Solution Implementation featuring full AR lining package tiered vibrators equipped ceramic labyrinth seals
Results Wear liner replacement extended cycle months Major frame component life projected exceed years Bearing changeout interval extended months

Usine de coke de pétrole calciné

Challenge The extreme abrasiveness of calcined CPC was wearing out standard screen components every month leading volatile maintenance schedules high inventory costs
Solution Implementation featuring full AR lining package tiered vibrators equipped ceramic labyrinth seals
Results Wear liner replacement extended cycle months Major frame component life projected exceed years Bearing changeout interval extended months

Usine de coke de pétrole calciné

Challenge The extreme abrasiveness of calcined CPC was wearing out standard screen components every month leading volatile maintenance schedules high inventory costs