1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Votre opération de manutention de coke est-elle confrontée à des goulots d'étranglement persistants et à des coûts croissants ?? L’étape de sélection est souvent un point d’échec critique, directly impacting downstream processing and overall plant profitability. Les défis courants incluent:

Aveuglant & Reporter: Moisture and fine coke particles adhere to screen decks, blinding apertures and forcing material to bypass the screening process. This leads to product contamination, inefficient size separation, and increased wear on crushers.
Temps d'arrêt excessif pour la maintenance: Frequent breakdowns of vibratory mechanisms, changement de toile d'écran, and structural fatigue repairs halt your entire production line. Unplanned downtime in a coke plant can cost tens of thousands per hour in lost throughput.
Consommation d'énergie élevée & Contrainte structurelle: Inefficient vibration systems draw excessive power while transmitting damaging forces to the support structure. This increases operational costs and creates longterm integrity concerns for the screening station.
Classement des produits incohérent: Variable feed rates and inefficient screen action result in offspec product. This can lead to rejected loads from steel mill customers or reduced efficiency in anode baking plants.

Are you evaluating a coke vibration screen manufacturer based on initial cost alone, or are you calculating the total cost of ownership—factoring in uptime, main d'oeuvre d'entretien, and energy efficiency?

2. APERÇU DU PRODUIT: Tamis vibrant à coke robuste

Cet équipement est d'une grande capacité, linear motion vibrating screen engineered specifically for the abrasive and demanding environment of met coke and petroleum coke sizing. Its design focuses on reliable separation of coke fractions (par ex., coke de haut fourneau, coca aux noix, brise) after crushing.

Flux de travail opérationnel:
1. Alimentation & Distribution: Le coke broyé est introduit dans la boîte d'alimentation robuste, which evenly distributes the material across the full width of the primary screen deck.
2. Positive Material Stratification: A dualshaft vibrator assembly generates a forceful linear motion. Cette action stratifie le lit de matière, forcing fines downward to contact the screen media while conveying oversize along the deck.
3. Séparation précise des tailles: Multiple deck levels (typiquement 13) equipped with tailored screen panels (grillage, polyuréthane, ou plaque perforée) separate the coke into precise size fractions (par ex., +50mm, 50mm+25mm, 25mm).
4. Décharge & Transport: Correctly sized fractions are discharged via dedicated chutes onto separate conveyors for stockpiling or direct loading.

Champ d'application: Dimensionnement primaire et secondaire des produits métallurgiques (rencontré) coke and petroleum (animal de compagnie) coke in steel plants, carbon anode plants, and bulk coke handling terminals.

Limites: Not designed for sticky materials without predrying or specialized deck treatments. Maximum feed size is limited by deck construction and impact resistance.

3. CARACTÉRISTIQUES PRINCIPALES

Système de terrasse modulaire | Base technique: Independently tensioned panel sections with quickchange clamping | Avantage opérationnel: Operators can replace worn panels in under 30 minutes per module without specialized tools or cutting torches. | Impact sur le retour sur investissement: Reduces screen cloth downtime by up to 70%, augmentation des heures de fonctionnement annuelles disponibles.

Dual CounterRotating Shaft Vibrator | Base technique: Two synchronized eccentric shafts generating a linear force vector along the center of mass | Avantage opérationnel: Provides aggressive material conveyance with minimal vertical force transmission to the support structure. | Impact sur le retour sur investissement: Lowers structural reinforcement costs by up to 40% and reduces bearing stress for longer service intervals.

HeavyDuty Side Plates & Cross Members | Base technique: Analyse par éléments finis (FEA)optimized steel fabrications with continuous welds | Avantage opérationnel: Withstands constant highimpact loading from large coke lumps without cracking or fatigue failure over a 10+ year design life. | Impact sur le retour sur investissement: Eliminates costly side plate replacement cycles every 23 years common in lighterduty screens.

Ensemble de roulements encapsulés contre la poussière | Base technique: Labyrinth seals combined with positivepressure purge nipples (facultatif) | Avantage opérationnel: Prevents abrasive coke dust from contaminating vibrator bearings, the most common cause of catastrophic drive failure. | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements d'en moyenne 300%, preventing unplanned stoppages exceeding $15k per incident.

Entraînement à fréquence variable (VFD) Compatibilité | Base technique: Standardized motor mounts and dynamically balanced vibrator assembly for variable speed operation | Avantage opérationnel: Allows operators to finetune amplitude/frequency for optimal efficiency with varying feed rates or moisture content from a central control room.| Impact sur le retour sur investissement: Optimizes power draw and screening efficiency; field data shows typical energy savings of 1525% versus fixedspeed screens.

Ensemble de doublure résistante à l'abrasion | Base technique: Bolton wear liners at all impact points made from AR400 steel or equivalent composite materials | Avantage opérationnel: Protects critical structural components from direct abrasion, preserving structural integrity.| Impact sur le retour sur investissement: Converts potential major structural repairs into simple liner replacements at 20% of the cost.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Industry Standard for Coke Screens | Notre solution de tamis vibrant pour coke | Avantage (% amélioration) |
| : | : | : | : |
| Temps de changement des panneaux de terrasse| 48 heures par pont (full weld/bolt) | <2 heures par pont (modular clamp system)| Jusqu'à 75% plus rapide |
| Durée de vie du roulement du vibrateur (L10)| ~8 000 12,000 heures d'ouverture| 24,000+ heures d'ouverture (with proper sealing)| ~100200% longer |
| Durée de vie en fatigue structurelle| Designed for ~60 million stress cycles| FEAoptimized for >100 million stress cycles| ~67% longer design life |
| Efficacité du dépistage (6séparation en mm)| Typiquement 8590% under ideal conditions| Réalise systématiquement 9295% efficiency in field tests| ~58% absolute improvement |
| Transmitted Dynamic Force| High dynamic load factor requiring heavy supports| Low dynamic force design via balanced mass system| Jusqu'à 35% less force transmitted |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: dépendant du modèle; standard units handle from 200 MTPH à plus 2,500 MTPH of dry crushed coke.
Configuration de la plate-forme d'écran: Célibataire, double, ou options triple pont; standard widths from 1.5m to 3m; lengths from 4m to over 9m.
Conduire & Pouvoir: Dual shaft vibrator driven by twin TEFC motors via Vbelts. La puissance totale installée varie de 15 kW à 75 kW depending on size/mass.
Vibration Characteristics: Linear stroke typically adjustable between 8mm – 11mm; frequency range of 750 1000 RPM.
Spécifications matérielles: Châssis principal construit en acier de construction S355JR; side plates are often thickergrade S355J2G3; wear surfaces lined with AR400 steel; arbres en acier allié à haute résistance.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C; capable of handling material temperatures up to 150°C with specific seal/bearing configurations.

6. SCÉNARIOS D'APPLICATION

Préparation des aliments pour hauts fourneaux d'aciéries

Défi: A major integrated steel mill experienced chronic blinding on their secondary coke screens due to seasonal moisture increases. This caused excessive 10mm fines ("brise") reporting to the BF skip fraction (>12%), disrupting furnace permeability.
Solution: Installation of two tripledeck linear motion screens featuring nonblinding polyurethane deck panels on lower decks combined with heated deck technology on top decks.
Résultats: Screening efficiency for 10mm removal improved from 84% à 96%. Fines content in BF feed stabilized below 5%, contributing to an estimated 2% reduction in specific coke rate within six months.

Usine de calcination de coke de pétrole

Défi: An anodegrade calciner needed precise sizing (30mm+15mm) of green petroleum coke but faced rapid wear of wire mesh panels every three weeks due to extreme abrasiveness.
Solution: Implementation of customdesigned vibrating screens using modular tensioned polyurethane panel systems with ultrahigh abrasion resistance ratings.
Results Screen panel life extended from three weeks to over fourteen weeks between changes Annual maintenance costs for screen media fell by approximately $65k per unit

Bulk Coke Handling Terminal

Challenge A transshipment terminal required highcapacity screening (>2200 MTPH) but had strict limitations on allowable dynamic load transferred into their existing elevated gallery structure
Solution Engineers specified low dynamic force linear motion screens incorporating outofbalance motors configured specifically for force cancellation
Results Required throughput was achieved while transmitted dynamic forces were measured at 28 below the gallery s design limits eliminating need for costly structural reinforcement

Considérations commerciales

Niveaux de tarification:
Tier I Standard Duty Units For capacities 1500 MTPH severe duty environments custom materials Quoted per project

Fonctionnalités facultatives:
Heated Screen Decks spray bars antiblinding systems
Advanced Sealing Packages including positive air purge systems
Full Stainless Steel Construction contact parts specific corrosion environments
Integrated Condition Monitoring Systems vibration temperature sensors

Forfaits de services:
Basic Package Standard warranty parts manual
Platinum Support Package Extended warranty priority parts dispatch annual health inspection reports
Full Service Contract Includes all scheduled maintenance parts labor performance audits fixed annual fee

Options de financement:
Capital Purchase Direct sale outright ownership
Lease To Own Programs Fixed term lease concluding transfer title suitable managing capital expenditure
Operating Lease Lower monthly payments equipment returned end term

FAQ

What if my existing feed chutes support structure don align perfectly with your standard dimensions We provide comprehensive interface drawings during quotation phase can manufacture custom adapter sections transition pieces ensure fit within your current layout at minimal additional cost

How does this screen handle wet sticky coke during rainy seasons While no vibrating screen eliminates all sticky material issues our combination open deck designs optional heated decks significantly reduces adhesion For severe conditions we recommend pre drying steps consult our engineering team specific recommendations

What is realistic expected lifespan main frame structure before major refurbishment Based operational history similar installations our FEA optimized frames show no signs fatigue cracking requiring repair years proper installation maintenance Bearings seals consumable components will require scheduled replacement

Can you supply compatible replacement screen panels our existing competitor s equipment Yes we manufacture tailor made tensioned modular panels fit most major OEM brands often higher wear resistant materials than original specification Provide model number detailed measurements quotation

Do you offer performance guarantees Field data allows us confidently guarantee screening efficiency percentage points specific cut size provided agreed upon consistent feed rate material characteristics Guarantees outlined detail commercial contract

What typical delivery lead time after order confirmation For Tier II heavy duty units standard configuration lead time ranges weeks depending current workload Tier III custom solutions require detailed engineering lead times start weeks Final schedules confirmed upon order

Are installation supervision commissioning services included Basic installation manuals detailed General Arrangement drawings included Optional site supervision commissioning engineer services available fixed daily rate ensure optimal startup performance