1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Is your coke handling operation losing profitability to inefficient screening? Common challenges with conventional screens directly impact your bottom line. Vivez-vous:
Excessive Product Loss: Fines and valuable coke breeze passing through worn or inefficient screen decks, représentant une perte de revenus directe pour chaque tonne traitée.
Temps d'arrêt pour maintenance élevé: Frequent failures of screen decks, roulements, or exciters due to the extreme abrasion and impact of coke, leading to unscheduled stoppages and production delays.
Aveuglant & Poor Efficiency: Moisture or sticky fines blinding screen meshes, réduisant considérablement la zone de criblage efficace et le débit, forcing recirculation and increasing energy costs.
Classement des produits incohérent: Unreliable particle size separation resulting in offspec product for blast furnace or foundry customers, risking contract penalties and reputational damage.
Problèmes d’intégrité structurelle: Constant, highimpact vibration leading to fatigue cracks in the screen body or support structure, creating major safety risks and costly capital repairs.

La question centrale pour les directeurs d'usine est: comment pouvez-vous obtenir des résultats précis, reliable coke classification while maximizing uptime and protecting your material yield?

2. APERÇU DU PRODUIT

The Export Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the dry classification of metallurgical coke and coke breeze. Designed for robustness in harsh environments, it separates crushed coke into precise size fractions critical for blast furnace efficiency and other industrial processes.

Flux de travail opérationnel:
1. Présentation du flux: Sized coke from crushers is evenly distributed onto the feed box of the vibrating screen.
2. Stratification & Séparation: Haute intensité, linear or circular vibration stratifies the material bed. Smaller particles descend to contact the screen cloth apertures, tandis que les particules plus grosses se déplacent sur la surface du pont.
3. Taille Fraction Décharge: Correctly sized particles pass through the screen mesh (sous-dimensionné), while oversized particles discharge at the deck end (surdimensionné). Multideck configurations allow for simultaneous separation into several product grades.

Champ d'application: Criblage primaire et secondaire du coke métallurgique, récupération de brise de coke, sizing for sinter plants, and prescreening for gasification processes.

Limites: Not designed for wet screening applications or for materials with extreme adhesive properties without specialized deck treatments.

3. CARACTÉRISTIQUES PRINCIPALES

Système de terrasse modulaire | Base technique: Les boules, subframe mounted polyurethane or rubber clad steel panels | Avantage opérationnel: Dramatically reduced replacement time; individual panels can be changed without full deck dismantling. | Impact sur le retour sur investissement: Réduit les temps d'arrêt pour maintenance planifiée jusqu'à 60%, augmentation des heures de fonctionnement annuelles.

HeavyDuty Exciter Assembly | Base technique: Internally mounted, greaselubricated vibrator unit with oversized bearings and labyrinth seals | Avantage opérationnel: Isolated from direct material impact; delivers consistent amplitude under variable load conditions. | Impact sur le retour sur investissement: Proven service intervals exceeding 8,000 hours under continuous operation, reducing spare part consumption.

Construction boulonnée Huck | Base technique: Highshear strength fastener system used throughout the main frame and side plates | Avantage opérationnel: Eliminates weld fatigue failures; creates a rigid, maintenancefree body structure resistant to crack propagation. | Impact sur le retour sur investissement: Prolonge la durée de vie structurelle de plusieurs années, éviter les coûts de remplacement prématurés des immobilisations.

Tiered Dust Enclosure | Base technique: Multisegment rubber skirtboard system with quickrelease clamps at multiple transfer points | Avantage opérationnel: Contains dust emission at feed, décharge, and side skirts; improves plant environmental compliance. | Impact sur le retour sur investissement: Mitigates material loss as airborne fines and reduces housekeeping labor requirements.

Suspension à ressort réglée | Base technique: Computermodeled coil spring or rubber buffer system matched to dynamic load parameters | Avantage opérationnel: Isole jusqu'à 85% des forces dynamiques de la structure porteuse; allows installation on elevated platforms. | Impact sur le retour sur investissement: Eliminates costly structural reinforcement needs during installation and minimizes vibration transmission.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Écrans conventionnels) | Export Coke Vibration Screen Solution | Avantage (% amélioration) |
| : | : | : | : |
| Durée de vie des panneaux de terrasse| 36 months with steel wire mesh | 1218 months with polyurethane clad panels | +150% amélioration moyenne |
| Disponibilité annuelle| ~8590% (including planned stops)| >94% (données de terrain documentées) |>4 percentage point gain |
| Efficacité du dépistage| 8590% on dry 6mm separation| Constamment >94% on same duty| +5% reduction in misplaced fines |
| Consommation d'énergie par tonne| Référence (100%)| Conduite optimisée & le bilan de masse réduit le tirage d'environ 15 %| 15% coût opérationnel inférieur |
| Installation & Temps de mise en service| 57 days for full assembly on site| Preassembled modules reduce field work to 23 jours|<50% of standard time |

5. SPÉCIFICATIONS TECHNIQUES

Capacité / Notation: Dépend du modèle; vont de 500 MTPH en 2,500 MTPH de coke sec (bulk density ~0.50.6 t/m³).
Exigences d'alimentation: Entraîner les moteurs de 15 kW à 45 kW par unité de vibrateur (généralement à double disque), 400/690V et, IP66 protection standard.
Spécifications matérielles:
Cadres de terrasse & Plaques latérales: Acier résistant à l'abrasion (AR400/450).
Plateformes d'écran: Modular polyurethane panels with embedded steel reinforcement; optional rubberclad steel or tensioned wire cloth.
Cadre principal & Cross Members: Heavywalled structural steel with corrosioninhibiting primer.
Dimensions physiques: Singledeck widths from 1.8m to 3.6m; longueurs de 4,8m à 7,2m.
Plage de fonctionnement environnementale: Température ambiante de 20°C à +45°C; designed for outdoor installation with appropriate electrical components.

6. SCÉNARIOS D'APPLICATION

Integrated Steel Plant Blast Furnace Feed

Challenge A major steel producer faced consistent fines (5mm) contamination in their BFgrade coke (2575mm), affecting furnace permeability and increasing coke rate.
Solution Installation of a primary Export Coke Vibration Screen with two decks following secondary crushing.
Results Achieved a clean +25mm product with less than 3% undersize contamination while recovering 5mm breeze for sinter plant use—a quantifiable reduction of $12/ton in effective BF feed cost.

Producteur de Coca-Cola Marchand

Challenge Offspec product batches due to inconsistent screening after rain events caused moistureinduced blinding on traditional screens.
Solution Implementation of our screens equipped with specialized antiblinding polyurethane decks featuring slotted apertures and balltray cleaning systems.
Results Screening efficiency remained above 92% even with surface moisture up to 7%, eliminating penalty clauses related to product sizing in supply contracts within one quarter.

7 CONSIDÉRATIONS COMMERCIALES

Export Coke Vibration Screens are offered in three primary tiers:

1. Série de service standard: For capacities up to ~800 MTPH. Includes core heavyduty construction features ideal for most merchant coke operations.
2. Série robuste: For capacities from ~800 MTPH to ~1,800 MTPH featuring enhanced exciter specifications and premiumtier bearing assemblies—the recommended choice for integrated steel plants.
3. Série extra-robuste: For ultrahighcapacity applications exceeding ~1，800 MTPH， incorporating duplex bearing exciters， conception de cadre renforcé，and premium dust sealing packages．

Optional features include stainless steel fasteners，full stainless steel skirting，integrated spray systems for limited dust suppression，and condition monitoring sensor ports．

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including scheduled inspections，analyse vibratoire，and guaranteed spare parts availability．Financing options including equipment leasing are available through accredited partners．

FAQ

Q What is the lead time for a typical Export Coke Vibration Screen?
A Lead times vary by model complexity．For standard configurations，expect delivery within X weeks upon order confirmation．Customized solutions may require additional engineering time．

Q Can this equipment integrate into our existing PLCcontrolled plant？
A Yes．All drives are compatible with standard industrial motor starters．The screen itself is supplied readyforsignal connection；it does not include complex control logic but can interface with your plant’s start/stop interlocks．

Q How does this design handle variations in feed rate？
A The exciter system generates a constant force independent of load．While efficiency is optimized at design capacity，field data shows performance degradation remains minimal (±2%) within a ±20% feed rate fluctuation．

Q What are the primary wear items？
A The primary consumables are the modular deck panels followed by wear liners on feed boxes．Spare parts kits based on recommended annual usage are available．

Q Do you provide installation supervision？
A Yes．Professional commissioning supervision is offered as an optional service package．This includes final alignment checks，initial startup assistance，and operator training．

Q Are your technical specifications guaranteed？
A All performance figures stated are based on standard test conditions using defined material characteristics．We provide written performance guarantees as part of our commercial proposal based on your specific application data sheet．

Q What financing structures do you offer？
A We work with thirdparty financial institutions that offer operating leases，capital leases/finance leases,and traditional purchase loans.Structures can be tailored over terms typically ranging from X years