1. PEMBUKAAN PAINPOINT DRIVEN

Adakah operasi pengendalian kok anda dibelenggu oleh kualiti produk yang tidak konsisten, penjanaan denda yang berlebihan, and unplanned maintenance halts? Bagi pengurus loji yang mengawasi pemeriksaan kok, common challenges directly impact profitability and throughput:
Pencemaran Produk & Rejections: Inefficient separation allows undersize fines to contaminate blast furnace feedstock or anodegrade product, leading to customer penalties and degraded metallurgical performance.
Premature Screen Deck Failure: The extreme abrasiveness of hot or cold coke accelerates wear on screen panels and support structures, menyebabkan kerap, costly replacements and production stoppages.
Membutakan & Pemindahan: Sticky coke particles and moisture can blind screen apertures, while insufficient vibration leads to material carryover, drastically reducing effective screening capacity and classification accuracy.
Keletihan Struktur & Penghantaran Getaran: Poorly engineered vibratory motion transmits damaging harmonics to the base frame and surrounding infrastructure, risking longterm structural integrity.

Are you seeking a screening solution engineered not just to move material, but to precisely classify it while withstanding the punishing environment of coke handling? The right bespoke vibration screen is a capital investment in predictable grading and operational continuity.

2. GAMBARAN KESELURUHAN PRODUK

A Bespoke Coke Vibration Screen is a heavyduty industrial screening machine specifically designed for the sizing, scalping, or dedusting of metallurgical coke (cold or hot) dan kok petroleum. Engineered from the ground up for this application, it replaces generic screens that fail under abrasive loads.

Aliran Kerja Operasi:
1. Suapan Terkawal: Coke is introduced via a regulated feed chute onto the screen’s inlet section, distributing load across the full deck width.
2. HighIntensity Stratification: A precisely tuned vibratory mechanism (typically dual eccentric shaft or bruteforce design) imparts a linear or elliptical motion, aggressively stratifying material. Fines are forced downward to contact the deck.
3. Pemisahan Tepat: Stratified particles pass through accurately sized screen panel apertures (Wire mesh, poliuretana, or perforated plate), separating into defined size fractions (mis., +50mm, 50mm+25mm, 25mm).
4. Pelepasan Cekap: Sized fractions discharge via dedicated chutes into separate collection conveyors or bins for downstream processing.

Skop Permohonan: Pemeriksaan primer dan sekunder kok metalurgi (blast furnace foundry), anodegrade petroleum coke, calcined coke. Suitable for sinter feed preparation and coke breeze recovery.
Batasan: Not designed for wet screening processes or as a replacement for crushers. Maximum feed temperature and particle size are defined by specific material specifications.

3. CIRI TERAS

Sistem Dek Modular | Asas Teknikal: Boltin panel subframes with tensioning rails | Faedah Operasi: Enables rapid changeover of worn screen media (<4 jam berbanding. 12+), minimizing downtime for maintenance crews. | Kesan ROI: Reduces labor costs per changeout by ~60% and increases annual available production time.

Hot Coke Design Package | Asas Teknikal: Internal aircooled bearing housings & heatresistant seals | Faedah Operasi: Allows continuous operation with coke feed up to 250°C without bearing lubrication failure or seal degradation. | Kesan ROI: Eliminates costly cooling periods before screening, increasing line throughput by maintaining process flow.

Antibuta & Wear Systems | Asas Teknikal: Integrated ball tray decks or tensioned wire mesh with polyurethane cleaners | Faedah Operasi: Continuous microimpact dislodges sticky particles; wearresistant liners on decks/sideplates extend service life in highabrasion zones. | Kesan ROI: Maintains nearoriginal capacity over longer campaigns; reduces consumable parts expenditure by 3040% setiap tahun.

Dynamically Tuned Vibratory Frame | Asas Teknikal: Analisis Unsur Terhingga (FEA) pengagihan tekanan yang optimum & isolation spring system | Faedah Operasi: Contains vibratory forces within the screen body; minimizes harmful transmission to supporting structures (<90% isolation efficiency). | Kesan ROI: Protects civil foundation investments and eliminates ancillary structural repairs.

DustEncapsulated Design | Asas Teknikal: Gasketed covers & dusttight discharge spouts with inspection ports | Faedah Operasi: Contains coke dust at transfer points, improving site air quality and reducing housekeeping labor. | Kesan ROI: Lowers environmental compliance risk and reduces cleanuprelated operational delays.

Condition Monitoring Prep | Asas Teknikal: Preinstalled sensor pads (getaran, suhu) on bearings with external junction box | Faedah Operasi: Facilitates easy integration into predictive maintenance programs for early fault detection. | Kesan ROI: Menghalang kegagalan galas bencana; enables planned shutdowns, avoiding 70+ hours of unplanned downtime per incident.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Generic Screen) | Bespoke Coke Vibration Screen Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Hayat Perkhidmatan Panel Dek| 36 months under abrasive load| 814 months with applicationspecific media| +130% ke +150% |
| Kecekapan Saringan| ~85% for 25mm separation| Secara konsisten >92% for same separation| +8% keuntungan mutlak |
| Masa Henti Tahunan untuk Penyelenggaraan Skrin| 120180 jam (pemeriksaan, perubahan)| 4060 jam (reka bentuk modular)| 65% pengurangan |
| Penggunaan Tenaga setiap Tan Disaring| Garis dasar (100%)| Jisim yang dioptimumkan & kecekapan memandu| 15% pengurangan |
| Membawa MTBF (Masa Min Antara Kegagalan)| ~12,000 hours in harsh service| >20,000 hours with cooling/sealing package| +67% penambahbaikan |

Screening Efficiency defined as ratio of correctly sized undersize material recovered vs. total undersize in feed.

5. SPESIFIKASI TEKNIKAL

Penilaian Kapasiti: bergantung kepada model; julat standard daripada 200 MTPH kepada 1,200 MTPH kok pukal (80 lbs/ft³).
Unit Pemanduan: Dual eccentric shaft mechanism with greaselubricated spherical roller bearings. Alternative bruteforce designs available for highcapacity scalping.
Keperluan kuasa: 15 kW kepada 55 motor kW (400V/50Hz atau seperti yang dinyatakan), IP66 rated.
Konfigurasi Dek: Bujang, berganda, or tripledeck layouts based on cut points.
Pilihan Media Skrin: Jaring dawai keluli karbon tinggi (hotgalvanized), panel modular poliuretana, perforated manganese steel plates.
Kerangka Struktur: Heavyduty carbon steel plate construction with internal ribbing; shotblasted and coated with industrial epoxy paint system.
Dimensi Fizikal (Typical DoubleDeck): Length ~7m x Width ~2.5m x Height ~3m (excluding supports).
Persekitaran Operasi: Direka untuk suhu ambien dari 20°C hingga +50°C; capable of processing material up to 250°C with hot package.

6. SENARIO APLIKASI

[Steel Mill Blast Furnace Feed] Cabaran: A major integrated steelmaker experienced high variability in blast furnace coke size fraction (50mm+25mm), leading to irregular gas flow and increased fuel rate penalties estimated at €500k annually.Penyelesaian: Implementation of a tripledeck bespoke coke vibration screen with precise aperture control ahead of the furnace bins.Keputusan: Achieved consistent sizing with <3% deviation in target fraction; reduced furnace fuel rate by 2%. Payback period was under 18 months via fuel savings alone.

[Loji Pengkalsinan Coke Petroleum] Cabaran: Anodegrade calciner needed to remove all 8mm fines from final product but faced rapid blinding of standard screens from residual volatiles.Penyelesaian: Installation of a bespoke linear motion screen featuring antiblinding ball trays and directheated deck panels.Keputusan: Sustained screening efficiency above 94%; eliminated manual deck cleaning shifts; increased saleable product yield by an estimated 4%.

7. PERTIMBANGAN KOMERSIL

Our Bespoke Coke Vibration Screens are offered in three primary tiers:
1. (Peringkat Asas): Standard Duty Screens, engineered core components with selectable media options—ideal for lowertonnage operations processing cooled coke.
2. (Peringkat Disyorkan): HeavyDuty Performance Screens, includes all core features listed above—the standard solution for most highvolume metallurgical applications requiring reliability.
3. (Peringkat Premium): SevereDuty Engineered Systems, includes full FEA analysis report customised feed/discharge hoods advanced instrumentation packages—specified for greenfield sites maximum operational data capture

Optional features include variable frequency drives process control integration custom skid bases extended warranty packages

Financing options include capital purchase lease agreements operating leases tailored support service packages provide scheduled inspections parts supply

8.Soalan Lazim

Q1 Is your bespoke vibration screen compatible existing conveyor feed hoppers
Our engineering team will review your existing layout interface drawings We design custom inlet transition sections flanges ensure a proper fit minimal retrofit required during installation

S2 Apakah garis masa pentauliahan pemasangan biasa
From arrival site mechanical installation electrical connection dry run commissioning typically requires days supervised our engineer Delivery lead times vary based specification

Q3 How does this equipment impact overall plant noise levels
Properly installed isolated screens operate within dB(A) range at meter distance meeting typical industrial environmental standards Acoustic enclosures are available option where required

Q4 What are payment terms delivery
Standard terms progress payment upon order confirmation payment prior shipment balance due upon completion Factory Acceptance Test Major projects may qualify structured milestone payments

Q5 Do you provide wear parts ongoing technical support
We maintain comprehensive inventory critical wear parts offer guaranteed hour dispatch key components Support packages include remote diagnostics annual health checks technician dispatches