1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Is your bulk material handling operation losing profitability to inefficient screening? Les défis courants liés aux cribles vibrants standard ont un impact direct sur vos résultats. Vivez-vous:
Excessive Downtime for Screen Cloth Changes: Frequent blinding and wear of screen media halts production, coûtant des milliers de dollars par heure en perte de production et de main d'œuvre.
Gradation du produit incohérente: Poor stratification and material carryover result in offspec product, conduisant à des refus de clients, frais de retraitement, et des matières premières gaspillées.
Entretien élevé & Coûts énergétiques: Inefficient drive systems and structural failures from unbalanced vibration demand constant attention and consume excessive power.
Flexibilité limitée des processus: A single screen cannot adapt to varying feed rates or material characteristics, forcing compromises in your entire process flow.

What if a screening solution could systematically address these issues, turning a cost center into a reliable efficiency driver?

2. APERÇU DU PRODUIT

The White Label Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the precise sizing and scalping of bulk materials like foundry coke, coke métallurgique, and similar aggregates. Its design focuses on durability and consistent performance in demanding mineral processing and material handling applications.

Flux de travail opérationnel:
1. Alimentation contrôlée: Material is evenly distributed across the full width of the screen inlet.
2. Stratification efficace: Le mouvement linéaire généré par le double vibrateur stratifie rapidement le matériau, forcing fines downward to the screen surface while conveying oversize toward the discharge end.
3. Accurate Separation: Sized fractions pass through precisely tensioned screen panels or are discharged as oversize at designated outlets.
4. Décharge continue: Separated material streams are conveyed away for further processing or stockpiling.

Champ d'application & Limites:
Idéal pour: Dry screening of coke (foundry, metallurgical), alimentation frittée, granulats recyclés, pierre concassée, and similar granular materials (typically 0.1mm to 150mm).
Limites: Not designed for wet screening processes, highly abrasive slurries, ou collant, claybound materials without significant modification.

3. CARACTÉRISTIQUES PRINCIPALES

Modular Screen Deck System | Base technique: Independently tensioned polyurethane or wire mesh panels on a rigid substructure | Avantage opérationnel: Les panneaux peuvent être remplacés individuellement sous 30 minutes without dismantling adjacent decks or feed boxes. | Impact sur le retour sur investissement: Réduit les temps d'arrêt pour maintenance planifiée jusqu'à 70% compared to bolteddown panel systems.

Dual CounterRotating Eccentric Shaft Drive | Base technique: Two synchronized vibrators generating a true linear motion with adjustable stroke | Avantage opérationnel: Provides optimal material travel speed and stratification with minimal transmitted dynamic loads to the support structure. | Impact sur le retour sur investissement: Lowers structural maintenance costs and reduces energy consumption per ton processed by an average of 1520%.

Isolation à ressorts hélicoïdaux robustes | Base technique: Multiple highcycle fatiguerated steel coil springs at each support point | Avantage opérationnel: Isole plus 95% des forces dynamiques, protecting the building structure and allowing for installation on elevated floors. | Impact sur le retour sur investissement: Eliminates the need for massive concrete foundations, reducing installation time and capital cost.

Conception fermée et étanche à la poussière | Base technique: Continuous sealing system between decks, plaques latérales, and discharge hoods | Avantage opérationnel: Contient les émissions de poussières à la source, improving plant safety and environmental compliance. | Impact sur le retour sur investissement: Lowers costs associated with external dust collection systems and reduces housekeeping labor.

Système de lubrification centralisé à la graisse | Base technique: Automated manifold delivering grease to all critical vibrator bearing points | Avantage opérationnel: Ensures optimal bearing life with minimal manual intervention from operators. | Impact sur le retour sur investissement: Extends bearing service intervals by 3x, prévenir les pannes catastrophiques et les arrêts imprévus.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Solution d'écran vibrant pour coke en marque blanche | Avantage (% Amélioration) |
| : | : | : | : |
| Temps de changement de support d'écran (Pont complet) | 812 heures (bolted system) | 50% plus rapide |
| Durée de vie des roulements (Système d'entraînement) | ~10,000 operating hours | >16,000 operating hours with centralized lube| >60% durée de vie plus longue |
| Consommation d'énergie (kWh/tonne) Baseline = X kW/Ton| X kW/Ton (standard circlethrow) X 0.85 kW/tonne (optimized linear motion)| ~15% more efficient |
| Transmission de force à la fondation| Haut; requires massive concrete base| <5% transmis; can use elevated steel support| Enables more flexible plant layout |

5. SPÉCIFICATIONS TECHNIQUES

Gamme de modèles & Capacité: Disponible en largeurs de 1,2 m à 3,6 m; longueurs de 4,8m à 10m. Capacités de 50 TPH à plus 1200 TPH en fonction de la taille de l'ouverture et de la densité du matériau.
Exigences d'alimentation: Les moteurs d'entraînement vont de 2 x 7.5 kW à 2 x 45 kW (400/690V, 50/60Hz). Isolation system requires no external power.
Spécifications matérielles: Main frame heavyduty carbon steel (S355JR). Side plates abrasionresistant steel (AR400). Deck frames galvanized steel or stainlesssteel options.
Dimensions physiques & Poids: Varie selon le modèle; typical footprint is Length (+20%) x Largeur (+10%) of screen deck nominal size. Weights range from ~5 tonnes to >25 tonnes.
Plage de fonctionnement environnementale: Température ambiante: 20°C à +45°C. Designed for indoor or sheltered outdoor installation with appropriate finishes.

6. SCÉNARIOS D'APPLICATION

Foundry Coke Production Plant – Final Product Sizing

Défi: A major foundry needed consistent +25mm 50mm lump coke but their existing screens suffered rapid blinding with fines (<5mm), causing offspec product batches every shift.
Solution: Installation of a twodeck White Label Coke Vibration Screen with top deck polyurethane panels (50mm aperture) and bottom deck wire mesh (25mm aperture).
Résultats: Achieved consistent product gradation (>98% dans les spécifications). Panel blinding was eliminated due to effective linear stratification; media change intervals extended from weekly to quarterly.

Integrated Steelworks – Sinter Plant Feed Preparation

Défi: Fluctuations in crusher output led to overload conditions on sinter feed screens downstream, causing frequent bearing failures and unscheduled downtime exceeding 40 heures par mois.
Solution: Deployment of a heavyduty model with oversized vibrator bearings rated for higher Gforces and an integrated loadsensing control system that adjusts feed rate via PLC interface.
Résultats: Field data shows a complete elimination of vibrationrelated bearing failures in the first year of operation. La disponibilité des plantes a augmenté de plus de 3%, translating directly to increased sinter production.

7 CONSIDÉRATIONS COMMERCIALES

White Label Coke Vibration Screens are offered under a tiered pricing structure based on size specifications:
Série Standard (13 Ponts): For most standard coke sizing duties; includes base motor options standard isolation springs dust covers
Série robuste: For hightonnage primary scalping or severeduty applications includes reinforced frames larger diameter shafts heavyduty bearings
Optional features include stainlesssteel contact parts variable frequency drives for stroke adjustment spray bar systems for limited antiblinding duty custom discharge hood designs

Service packages range from basic commissioning supervision through comprehensive multiyear maintenance agreements including parts kits remote monitoring support Financing options including equipment leasing are available through certified partners

FAQ

Q1 How does this vibration screen handle variations in feed rate?
A1 The linear motion design provides consistent conveying velocity even under variable load conditions For extreme variations an optional variable frequency drive allows operators finetune stroke amplitude ensuring separation efficiency across different throughputs

Q2 What is compatibility existing screen cloth inventory?
A2 Our modular deck system uses standardized tensioning rails accommodating most commercially available polyurethane panel hookstyles wire mesh types This minimizes need complete media replacement during initial transition

Q3 What typical installation timeline look like?
A3 Most units require minimal foundation work due effective isolation Preassembled modules reduce onsite assembly time Typical installation commissioning period ranges days weeks depending complexity existing plant infrastructure

Q4 How does operational noise level compare other screens?
A4 Enclosed design combined coil spring isolation typically results sound pressure levels below dB(UN) measured meter from machine meeting most stringent workplace health safety regulations

Q5 What warranty provided key components?
A5 Standard warranty covers defects materials workmanship months operation Vibrator assemblies drive motors carry extended month warranty when registered our service program

Q6 Can this screen integrate our existing PLC control system?
A6 Yes units come equipped standard motor starters protection but can furnished with interfaceready control panels providing run status fault alarms remote start stop capability facilitating integration central control room

Q7 Are spare parts readily available longterm?
A7 We maintain global inventory critical wear parts vibrator shafts bearings deck components ensuring availability minimize potential extended downtime