Coke Vibration Screen ODM Manufacturer
1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR
Votre opération de manutention de coke est-elle en proie à des goulots d'étranglement persistants, coûts d'entretien excessifs, et qualité des produits incohérente? Pour les directeurs d'usine supervisant le criblage du coke, common challenges directly impact the bottom line:
Aveuglant & Temps d'arrêt: Bien, les particules de coke humides adhèrent aux plateaux de criblage, provoquant une cécité rapide. This reduces effective screening area by up to 40%, forcing frequent shutdowns for manual cleaning and slashing throughput.
Usure prématurée & High OPEX: La nature abrasive du coke métallurgique accélère l’usure des panneaux de criblage, ponts, et excitateurs. Unplanned component replacements and associated labor can increase annual maintenance budgets by 25% ou plus.
Séparation inefficace des amendes: Inadequate vibration dynamics lead to poor segregation of breeze (coke fines under 10mm). This results in product contamination, lost revenue from missized material, and potential downstream process issues.
Fatigue structurelle & Transmission des vibrations: High Gforces needed for effective screening transmit damaging vibrations to the support structure and surrounding equipment, leading to cracks, foundation issues, and safety concerns.
Are you searching for a robust screening solution that delivers consistent uptime, lowers total cost of ownership, and ensures precise size separation for your coke product?
2. APERÇU DU PRODUIT
The Coke Vibration Screen is a heavyduty industrial screening machine engineered for the highcapacity sizing and scalping of metallurgical coke in battery, quenching, and sorting stations. Its core function is to separate crushed coke into precise fractions (par ex., coke de haut fourneau, coca aux noix, brise) tout en supprimant efficacement les amendes.
Flux de travail opérationnel:
1. Alimentation & Distribution: Crushed coke is uniformly fed onto the inlet end of the inclined screen deck via a chute or feeder.
2. Stratification & Séparation: Haute intensité, linear or elliptical vibration stratifies the material bed. Smaller particles pass through precisely sized deck apertures; oversized particles travel across the deck surface.
3. Décharge: Correctly sized fractions are discharged via separate outlets—oversize to crushers for recirculation or as product, undersize as breeze or product—ensuring a clean separation.
Champ d'application: Primary sizing of metallurgical coke after crushing; scalping of oven discharge; dedusting and fines removal; recovery operations.
Limites: Not designed for sticky materials without specialized deck technology; maximum feed size is constrained by deck opening and machine design; requires controlled feed rate for optimal efficiency.
3. CARACTÉRISTIQUES PRINCIPALES
Système de pont robuste | Base technique: Modular polyurethane or rubberclad steel panels with reinforced fixing | Avantage opérationnel: Dramatically increased service life under abrasive conditions; reduced noise levels (by ~10 dBA); panels are easily replaced in sections minimizing downtime | Impact sur le retour sur investissement: Cuts panel replacement costs by up to 60% over traditional woven wire decks.
AntiBlinding Technology | Base technique: Integrated ball tray decks or ultrasonic screen mesh cleaning systems | Avantage opérationnel: Continuous microimpact dislodges lodged particles near aperture openings maintaining nearoriginal open area | Impact sur le retour sur investissement: Sustains design capacity throughput reduces cleaning downtime by over 70%.
Balanced Elliptical Vibration | Base technique: Twin shaft exciter with outofphase synchronized weights generating an elliptical throw pattern | Avantage opérationnel: Optimized material travel speed with sharp stratification enhances separation accuracy especially for midrange sizes (1030mm) | Impact sur le retour sur investissement: Improves product purity by an average of 15% reducing recrush load and maximizing premium fraction yield.
Conception fermée et étanche à la poussière | Base technique: Gasketed side plates and dust hood connections with integral skirt boards | Avantage opérationnel: Contains airborne coke dust at transfer points improving site air quality meeting environmental standards | Impact sur le retour sur investissement: Lowers housekeeping costs mitigates health safety risks avoids potential regulatory noncompliance fines.
Cadre vibrant isolé | Base technique: Dynamic vibration isolators (rubber or spring) between the vibrating body and stationary base frame | Avantage opérationnel: Absorbe plus 95% of dynamic forces preventing transmission to supporting structures eliminates fatigue failures | Impact sur le retour sur investissement: Removes need for massive dedicated foundations reduces installation time capital cost protects plant infrastructure integrity.
Centralized Greasing Lube System | Base technique: Manifold with lines feeding all major bearing points from a single access port | Avantage opérationnel: Enables safe rapid lubrication during brief pauses extends bearing life under highload hightemperature conditions | Impact sur le retour sur investissement: Standardizes preventive maintenance intervals reduces bearing failure rates by an estimated 40%.
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Norme de l'industrie | Solution d'écran vibrant pour coke | Avantage (% amélioration) |
|||||
| Deck Panel Lifespan | Woven wire mesh lasts 23 mois sous forte abrasion | Polyurethaneclad modular panels last 812 mois | +300% durée de vie |
| Efficacité du dépistage | ~85% efficiency for midsize separation due to blinding | Maintient >92% efficiency via antiblinding systems | +78% efficacité durable |
| Temps d'arrêt pour maintenance | 812 hours monthly for cleaning bearing checks panel replacement
| Energy Consumption per Ton ~0.12 kWh/ton processed
| Breeze (10mm) Contamination in Product Fraction
5. SPÉCIFICATIONS TECHNIQUES
Capacité / Notation: Modèle dépendant de 200 TPH à plus 1500 TPH throughput capacity standard designs available
Exigences d'alimentation: Drive motor range from 7.5 kW à 45 kW depending on screen size mass excitation force
Spécifications matérielles: Highstress frame components S355JR steel side plates wear liners Hardox®400 Abrasionresistant polyurethane rubber composite deck materials
Dimensions physiques (Modèle typique): Deck Size (Lxl): 3m x1 .5m Overall length:~4 .2m Overall width:~2 .8m Height:~1 .6m Weight:~6500kg
Plage de fonctionnement environnementale: Température ambiante:20°C +50°C Feed material temperature upto120°C(maximum) Weather protection IP65 enclosure optional
6. SCÉNARIOS D'APPLICATION
Metallurgical Coke Plant Blast Furnace Feed Preparation Challenge:: Existing screens blinded within hours due high moisture content in quenched coke causing severe bottleneck before furnace feed bins resulting in inconsistent size distribution affecting furnace efficiency
Solution:: Installation two large doubledeck Coke Vibration Screens equipped ball tray antiblinding decks isolated base frames
Résultats:: Screening availability increased from94%. Blast furnace feed consistency improved quantified as+/5mm size variation reducedby30%. Annual maintenance labor hours decreasedby1200
Coke Sorting Terminal Product Diversification Challenge:: Terminal needed produce three distinct saleable products(>50mm2550mm<25mm)from single feed stream but existing separator generated excessive fines(<10mm)in midrange fraction reducing its market value
Solution:: Implementation multislope Coke Vibration Screen with precision elliptical vibration finetuning deck tensioning system
Résultats:: Product purity each fraction achieved>95%. Revenue from midrange(2550mm)fraction increasedby18%due reduced fines content System handled variable feed rates without performance degradation
7. CONSIDÉRATIONS COMMERCIALES
Niveaux de tarification des équipements: Entrylevel standard duty screens(starting~$25000);Heavyduty customengineered units($65000$200000+)based size configuration options
Fonctionnalités facultatives / Mises à niveau: Stainless steel construction critical areas hotmaterial handling kits spray bar systems different deck types(harps tensioned polyurethane etc.) variable frequency drives advanced condition monitoring sensors
Forfaits de services: Tiered annual maintenance contracts covering inspection parts discounts priority support Extended warranty available upto36months Comprehensive training programs operational maintenance staff included
Financing Options Available through partners include equipment leasing longterm rental purchase plans tailored capital expenditure cycles Project financing considered largescale installations
8. FAQ
Q1 How do we determine correct screen size deck configuration our specific capacity requirements?
Our engineering team requires your detailed feed rate particle size distribution(P80 D50)desired product splits moisture content This data allows us model recommend optimal machine specifications guarantee performance
Q2 Can this equipment integrate our existing PLC control system material handling network?
Yes standard designs include control panel compatible common industrial protocols(Profibus Ethernet/IP etc.) We provide necessary interface documentation facilitate integration your plant SCADA system
Q3 What typical installation timeline foundation requirements?
With isolated design foundation requirements less stringent than older screens Typical installation including positioning electrical mechanical connection commissioning takes510working days depending complexity Preinstallation foundation drawings issued advance
Q4 Are spare parts readily available what expected lead times?
We maintain strategic inventory critical wear parts(decks bearings exciters)at regional hubs Standard parts ship within48hours Custom components have lead times communicated upfront during purchase Longterm supply agreements ensure ongoing support
Q5 How does equipment handle variations feed rate material composition?
Robust design accommodates reasonable fluctuations Variable speed drive option allows operators adjust vibration intensity optimize performance realtime changing conditions ensuring consistent output quality