Коксын чичиргээт дэлгэц: HighCapacity Sizing Solutions for Metallurgical Coke Processing

Үйл ажиллагааны сорилт: When Screen Reliability Becomes Your Bottleneck

Every ton of metallurgical coke that fails to meet size specifications represents lost revenue, гэрээний торгууль, and downstream process disruption. Plant managers across the steel and foundry industries face the same recurring problems:

• Нүд сохлох, бэхлэх — Moisture content in quenched coke causes fines to adhere to screen media, хүртэл үр дүнтэй скрининг хийх талбайг багасгах 40% within a single shift
• Structural fatigue — The abrasive, highimpact nature of coke handling causes premature failure of screen decks, with typical replacement cycles of 6–9 months under continuous operation
• Сул зогсолтын зардал — Every hour of unscheduled screen downtime in a 1.5 MTPA coke plant translates to approximately $4,800 in lost production value, not including maintenance labor and replacement parts
• Тохиромжгүй бүтээгдэхүүний чанар — Offspec coke fractions (хэт том >75mm or undersize <25мм) trigger customer rejections and rescreening costs that erode already thin margins
• Vibration transmission — Poorly designed screen mounts transfer harmful vibrations to support structures, accelerating wear on conveyors and chutes

Your screening equipment must handle 200–300 tph of abrasive, hightemperature coke while maintaining separation efficiency above 90%. Can your current system deliver that consistently, shift after shift, without unscheduled interruptions?

Бүтээгдэхүүний тойм: The Coke Vibration Screen

Коксын чичиргээт дэлгэц нь хүнд даацын, linearmotion vibrating screen engineered specifically for the classification of metallurgical coke, цутгах үйлдвэрийн кокс, and petroleum coke at capacities from 50 нь 400 цагдаа. This equipment performs dry sizing of coke fractions at ambient or elevated temperatures (up to 120°C) without requiring water sprays or additional processing aids.

Үйл ажиллагааны ажлын урсгал

1. Тэжээлийн хуваарилалт — Coke enters the screen through a feed chute, where an integrated distribution plate ensures even material spread across the full deck width, preventing localized overloading and maximizing screening efficiency
2. Давхаргалалт — The linear motion (amplitude 6–10mm, frequency 750–900 rpm) causes smaller particles to migrate downward through the material bed, establishing contact with the screen surface
3. Хэмжээ тусгаарлах — Material passes over woven wire mesh or polyurethane panels with apertures from 10mm to 80mm, separating into oversize, дунд хэмжээтэй, болон бага хэмжээний бутархай
4. Ахах — Three independent discharge spouts direct each fraction to dedicated conveyors or storage bins, with optional dust collection hoods for environmental compliance
5. SelfCleaning Action — The combination of high acceleration (4.5–5.5 G) and specialized ball deck assemblies continuously clears apertures, maintaining open area throughout the shift

Хэрэглээний хамрах хүрээ

This screen is suitable for coke breeze recovery, самар кокс ялгах (10-25 мм), foundry coke sizing (25–80mm), and blast furnace coke classification. It operates effectively with feed moisture up to 12% (quenched coke) and feed temperatures up to 120°C. The equipment is not recommended for wet screening applications or for materials with more than 15% шавар агуулга.

Үндсэн шинж чанарууд

HighG Linear Motion Exciter | Техникийн үндэслэл: Dualshaft counterrotating exciter generating linear vibration at 4.5–5.5 G acceleration | Үйл ажиллагааны ашиг тус: Aggressive stratification separates nearsize particles that typically cause inefficiency in circularmotion screens | ROI нөлөө: Screening efficiency improves from industryaverage 85% to 93–95%, замаар эргэлтийн ачааллыг бууруулах 30%

Модульчлагдсан тавцангийн систем | Техникийн үндэслэл: Boltin polyurethane or wire mesh panels with quickrelease tensioning | Үйл ажиллагааны ашиг тус: Your maintenance crew can replace a worn deck section in 45 минутын эсрэг 4 гагнуурын загварт зориулсан цаг | ROI нөлөө: Annual maintenance labor savings of $12,000–$18,000 per screen, нэмэх 15 жилд нэмэлт ажлын цаг

SelfCleaning Ball Decks | Техникийн үндэслэл: Rubber balls in pockets beneath the screening surface, дэлгэцийн чичиргээгээр идэвхждэг | Үйл ажиллагааны ашиг тус: Continuous aperture clearing prevents blinding from moist coke fines, maintaining effective open area above 85% | ROI нөлөө: Eliminates manual cleaning stops, recovering 2–3 hours of production per week

Хүнд даацын бүтцийн хүрээ | Техникийн үндэслэл: S355J2 steel side plates (minimum 12mm thickness) with stressrelieved welded construction and finite element analysis validation | Үйл ажиллагааны ашиг тус: Хүрээний үйлчилгээний хугацаа хэтэрсэн 15 years under continuous 24/7 мэс засал, even with impact loading from feed chutes | ROI нөлөө: Replacement cost avoidance of $45,000–$60,000 per screen over a decade

Adjustable Stroke and Angle | Техникийн үндэслэл: Exciter weights adjustable in 5° increments; screen inclination adjustable from 0° to 15° | Үйл ажиллагааны ашиг тус: Your operators can finetune retention time and bed depth to match specific coke moisture and size distribution changes | ROI нөлөө: Optimized settings improve throughput by 8–12% without additional energy consumption

Нэгдсэн тоосжилт | Техникийн үндэслэл: Bolted dust covers with rubber seals and optional negativepressure extraction ports | Үйл ажиллагааны ашиг тус: Meets EPA particulate emission standards (PM10 < 50 мг / м³) without external enclosure costs | ROI нөлөө: Avoids $25,000–$40,000 in separate dust collection hood fabrication and installation

Vibration Isolator Mounts | Техникийн үндэслэл: Composite coil spring and rubber isolators with 95% vibration reduction efficiency | Үйл ажиллагааны ашиг тус: Transmitted dynamic forces to support structures are reduced to 5% of input, protecting adjacent equipment | ROI нөлөө: Extends conveyor and chute life by 3–5 years, saving $8,000–$15,000 in structural reinforcement costs

Өрсөлдөх давуу тал

| Гүйцэтгэлийн хэмжүүр | Аж үйлдвэрийн стандарт | Кокс чичиргээний дэлгэцийн шийдэл | Давуу тал (% Сайжруулалт) |
|||||
| Скрининг үр ашиг (at 50mm cut point) | 85-88% | 93-95% | 6-8% илүү |
| Deck Replacement Time | 4–6 hours | 45–90 minutes | 60-75% илүү хурдан |
| Frame Service Life | 8–10 years | 15+ жил | 50% илүү урт |
| Төлөвлөөгүй завсарлага (жил бүр) | 120–180 hours | 40-60 цаг | 60–70% reduction |
| Effective Open Area (after 8h operation) | 55-65% | 85-90% | 30–40% better |
| Дуу чимээний түвшин 1 м | 95–100 dB(Аг) | 85–88 dB(Аг) | 10–12 dB(Аг) доогуур |
| Боловсруулсан тонн тутамд эрчим хүчний хэрэглээ | 0.35–0.45 kWh/t | 0.25–0.30 kWh/t | 20–30% less |

Техникийн үзүүлэлт

| Зөнийн тавь чанар | Лал дох үйл |
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| Загварын хүрээ | CVS15 (15 м²), CVS20 (20 м²), CVS25 (25 м²) |
| Хүчин чадлын хүрээ | 50–150 tph (CVS15), 100–250 tph (CVS20), 150-400 т/цаг (CVS25) |
| Таслах цэгийн хүрээ | 10-80 мм (adjustable via deck configuration) |
| Дэлгэцийн тавцангийн тохиргоо | 1, 2, эсвэл 3 тавцан (depending on fraction requirements) |
| Чичиргээний давтамж | 750–900 rpm (VFD-ээр тохируулж болно) |
| Далайц (Имкс) | 6-10 мм (тохируулах боломжтой) |
| Хурдасгал | 4.5–5.5 G |
| Screen Inclination | 0° to 15° (тохируулах боломжтой) |
| Миний биарын хүчин | 2 × 15 kw (CVS15), 2 × 22 kw (CVS20), 2 × 30 kw (CVS25) |
| Хүчдэл | 380Т / 660Т / 3үе шат / 50Hz or 60Hz (custom available) |
| Side Plate Material | S355J2 бүтцийн ган, 12–16mm thickness |
| Дэлгэцийн медиа сонголтууд | Woven wire mesh (mild steel or stainless), полиуретан хавтан (80 Шор А), резинэн хавтан |
| Уургийн хэмжээ (Хамгийн их) | 150 мм |
| Feed Temperature (Хамгийн их) | 120°C continuous |
| Чийгээр тэжээх (Хамгийн их) | 12% (quenched coke) |
| Ерөнхий хэмжээсүүд (CVS20) | 6.5m L × 3.2m W × 2.8m H |
| Нийт жин (CVS20) | 18,500 кг |
| Ашиглалтын температурын хүрээ | 10°C-аас +50 °C хүртэл (орчин) |
| Тоос ялгаруулалт (with covers) | PM10 < 50 мг / м³ |
| Дуу чимээний түвшин 1 м | 85–88 dB(Аг) |
| Чичиргээ тусгаарлах үр ашиг | 95% |

Хэрэглээний хувилбарууд

Integrated Steel Plant — Blast Furnace Coke Sizing | Сорилт: Аг 2.8 MTPA steel plant experienced 14% offspec coke (хэт том >75мм) reaching the blast furnace, causing burden distribution problems and increasing coke rate by 18 кг/тГМ | Хариу: Installation of two CVS20 screens in parallel, configured with 75mm top deck and 25mm bottom deck, хүнсний бүтээгдэхүүний боловсруулалт 220 tph тус бүр | Үр дүн: Offspec coke reduced to 3.5%, коксын хувь хэмжээгээр буурсан 12 кг/тГМ, annual fuel cost savings of $2.1 сая, screen availability maintained at 96.5% гүйцээх 18 сар

Foundry Coke Producer — Nut Coke Recovery | Сорилт: A foundry coke producer was discarding 8,000 tpy of 10–25mm nut coke as waste due to inefficient screening, төлөөлж байна $640,000 in lost revenue annually | Хариу: Implementation of a CVS15 screen with polyurethane panels (10mm and 25mm apertures) and ball deck cleaning system | Үр дүн: Nut coke recovery increased to 92% of available material, үүсгэж байна $590,000 in new revenue in the first year, эргэн төлөгдөх хугацаа 7 сар

Coke Breeze Processing — Sinter Plant Feed | Сорилт: A sinter plant required consistent 0–6mm coke breeze at 85 цагдаа, but existing screens delivered only 68 tph with frequent blinding from 9% чийг агууламж | Хариу: Deployment of a CVS15 screen with 6mm stainless wire mesh and highG exciter (5.2 Гэр) to overcome moisture adhesion | Үр дүн: дамжуулалт хүртэл нэмэгдсэн 82 цагдаа (20% сайжруулалт), moisturerelated downtime reduced from 14 hours/month to 2 цаг/сар, sinter plant productivity improved by 4.5%

Арилжааны асуудал

Үнийн шатлал

| Тохиролцоо | Үнийн хүрээ (Гурш) | Зорилтот програм |
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| Стандарт (CVS15, нэг тавцан, төмөр тор) | $85,000–$110,000 | Basic coke breeze screening |
| Сайжруулсан (CVS20, давхар тавцан, полиуретан хавтан, тоос бүрхэвч) | $145,000–$185,000 | Blast furnace coke classification |
| Дээд зэрэглэлийн (CVS25, гурвалсан тавцан, full dust containment, VFD хяналт, алсаас хянах) | $220,000–$280,000 | Highcapacity integrated steel plants |

Нэмэлт шинж чанарууд

• VFD хяналтын багц ($8,500-12 мянган доллар) — Enables frequency adjustment for variable feed conditions
• Алсын хяналтын систем ($6,000–$9,000) — Realtime vibration, хэм, and bearing health data via Modbus or Profibus
• CeramicLined Feed Box ($4,500-7000 доллар) — Extends wear life in highimpact feed zones by 3×
• Сэлбэг хэрэгслийн иж бүрдэл ($12,000-18 мянган доллар) — Includes exciter bearings, тээврийноор, дэлгэцийн самбар, and tensioning hardware for 12 үйл ажиллагааны сар

Үйлчилгээний багцууд

| Багц | Хамрах хүрээ | Жилийн зардал (Гурш) |
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| Үндсэн | 2 урьдчилан сэргийлэх засвар үйлчилгээ хийх айлчлал, утасны дэмжлэг, 48цагийн эд анги илгээх | $9,500 |
| Стандарт | 4 урьдчилан сэргийлэх засвар үйлчилгээ хийх айлчлал, onsite repair within 24 цаг, тэргүүлэх ач холбогдол бүхий эд ангиудыг хүргэх, жилийн гүйцэтгэлийн аудит | $18,000 |
| Цогц | Unlimited technical support, 12цагийн газар дээр хариу өгөх, бүрэн эд ангийн бараа материалын менежмент, quarterly performance optimization | $32,000 |

Санхүүжилтийн сонголтууд

• Үйл ажиллагааны түрээс — 36–60 month terms with option to purchase at fair market value; -аас сарын төлбөр $2,400
• Тоног төхөөрөмжийн санхүүжилт — 10–20% down payment, -аас тогтмол ханш 6.5% 4-р сар, хүртэлх нөхцөл 84 сар
• PerformanceBased Contract — Payperton processed with minimum throughput guarantee; ideal for contractors with variable production volumes

Түгээмэл асуултууд

Q: Can the Coke Vibration Screen handle feed material directly from a coke wharf without prescreening?

Аг: Тиймээ. The screen is designed to accept feed directly from wharf conveyors with lump sizes up to 150mm. The feed box includes an impactabsorbing liner and distribution plate that spreads material evenly across the deck. Гэхдээ, for feed containing >5% tramp metal or oversized lumps above 150mm, we recommend installing a grizzly or magnetic separator upstream to prevent deck damage.

Q: What is the typical installation timeline from order to commissioning?

Аг: Standard delivery is 10–12 weeks from order confirmation. Site installation typically requires 5–7 working days with a twoperson crew, assuming prepared foundations and electrical connections. Commissioning and operator training add 2–3 days. For expedited projects, a 6week delivery option is available at a 10% нэмэлт төлбөр.

Q: How does the screen perform with varying moisture content in quenched coke?

Аг: Талбарын өгөгдөл 14 installations shows that screening efficiency remains above 90% хүртэл чийгийн хувьд 10%. Between 10–12% moisture, efficiency decreases to 85–88%, which is still above industry average. The ball deck cleaning system prevents aperture blinding, but we recommend maintaining feed moisture below 12% оновчтой гүйцэтгэлийн хувьд. For consistently higher moisture, consider a predrying step or heated screen option.

Q: What maintenance intervals should we plan for?

Аг: Under continuous 24/7 мэс засал, the following schedule applies: exciter bearing inspection every 2,000 цаг (replacement at 8,000–10,000 hours), screen panel inspection weekly (replacement every 6–12 months depending on abrasiveness), spring isolator check monthly (replacement at 3–5 years), and structural weld inspection annually. The comprehensive service package includes all scheduled maintenance, reducing your planning burden.

Q: Can the screen be retrofitted into an existing screening station with different footprint dimensions?

Аг: Тиймээ. Our engineering team can adapt the base frame and support structure to match your existing foundation within ±300mm dimensional tolerance. We require a site survey drawing and structural assessment before manufacturing. Retrofit installations typically cost 8–12% more than new installations due to custom adaptation work.

Q: Ямар баталгаат даатгалд хамрагдах вэ?

Аг: The standard warranty covers 24 ашиглалтад орсноос хойшхи сар буюу 30 тээвэрлэлтээс хойш сар, аль нь түрүүлж тохиолдоно. Coverage includes exciter assembly, хажуугийн хавтан, cross members, and vibration isolators. Screen panels and wear liners are excluded as consumable items. Extended warranty options are available up to 60 months through the Comprehensive service package.

Q: How does the energy consumption compare to our existing circularmotion screens?

Аг: The linearmotion design is inherently more energyefficient. Measured consumption is 0.25–0.30 kWh per ton processed, compared to 0.35–0.45 kWh/t for comparable circularmotion screens. Үйлдвэрийн боловсруулалтын хувьд 200 tph over 7,000 operating hours annually, this represents 140,000–280,000 kWh in annual savings, equivalent to $14,000–$28,000 at typical industrial electricity rates.

Q: What is the lead time for replacement screen panels?

Аг: Standard wire mesh panels are available from stock with 48hour dispatch. Polyurethane panels require 3–4 weeks manufacturing lead time. We recommend maintaining a spare set of panels for your critical deck (approximately $4,000–$6,000 depending on configuration) to eliminate downtime risk. Our parts inventory program can manage this automatically.