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Is Inconsistent Coke Sizing Costing You $50,000+ Per Shift in Rejects and Downtime?

In the metallurgical and petroleum coke processing industry, a single screen deck failure or a 2% deviation in particle size distribution can halt a calciner or disrupt a downstream anode plant. You face the daily challenges of:

• Blinding and Peening: melekit, highmoisture coke fines clogging standard screens, reducing effective open area by up to 40%.
• Keletihan Struktur: Constant highGforce vibration cracking welds on nonreinforced frames, leading to unplanned 12hour maintenance shutdowns.
• Inconsistent Cut Points: Inefficient stratification causing oversize material to contaminate fines, forcing recrushing cycles that waste energy and wear out crushers.
• Risiko Pematuhan Keselamatan: Operating without proper CE certification exposes your plant to regulatory fines and liability for worker safety.

Can your current screening equipment handle the abrasive, highimpact nature of green and calcined coke while maintaining a precise 6mm to 50mm separation? If not, your profit margin is being screened out.

Gambaran Keseluruhan Produk: The CE Marked Coke Vibration Screen Distributor

Ini adalah tugas berat, linearmotion vibratory screener specifically engineered for the classification and distribution of petroleum coke, kok metalurgi, dan kok faundri. It is designed to handle hightonnage feed streams (hingga 500 Tph) while providing a precise, multideck separation.

Aliran Kerja Operasi:
1. Kemasukan Suapan: Raw coke enters the distributor via a chute, landing on a wearresistant feed box to disperse the material evenly across the full screen width.
2. Stratifikasi: Highamplitude, lowfrequency vibration (700900 Rpm) causes heavier, larger particles to rise to the top layer, while fines migrate to the bottom deck.
3. Pengelasan: Material passes through a series of polyurethane or heavyduty woven wire mesh decks (biasanya 24 dek) untuk saiz yang tepat (mis., +50mm, 2550mm, 1025mm, 10mm).
4. Pengedaran: Sized fractions are discharged through dedicated spouts, directly feeding downstream conveyors, tong simpanan, or calcining kilns.
5. Oversize Reject: Bahan besar (+50mm) is directed to a crusher circuit or reject chute.

Skop Permohonan: Ideal for green coke handling at refineries, calcined coke processing at anode plants, and blast furnace coke sizing at steel mills.
Batasan: Tidak disyorkan untuk basah, sticky materials with >15% surface moisture without the addition of a heated deck or ball tray cleaning system.

Ciri Teras

Perhimpunan Penguja Tugas Berat | Asas Teknikal: Dualshaft, counterrotating gearbox | Faedah Operasi: Generates a linear stroke of 1014mm, ensuring deep bed stratification without vertical lift | Kesan ROI: Reduces power consumption by 15% compared to circular motion screens, lowering annual energy costs by $8,000$12,000

CE Certified Structural Integrity | Asas Teknikal: Analisis Unsur Terhingga (FEA) designed side plates with 10mm thick Strenx 700 keluli | Faedah Operasi: Eliminates frame cracking under continuous 24/7 operasi | Kesan ROI: Extends equipment lifespan to 15+ tahun, reducing capital replacement costs by 30%

Panel Skrin Poliuretana Modular | Asas Teknikal: Slotopening, abrasionresistant polyurethane (Shore A 90) | Faedah Operasi: Reduces blinding from coke fines; panels are interchangeable in 15 minit | Kesan ROI: Increases screen deck life by 3x over woven wire, penjimatan $4,500 annually in mesh replacement and labor

Integrated Feed Distributor Box | Asas Teknikal: Angled, replaceable AR400 steel liners | Faedah Operasi: Prevents material segregation at the feed point, ensuring even load distribution | Kesan ROI: Meningkatkan kecekapan saringan dengan 812%, reducing recirculating loads and energy waste

Sistem Pelinciran Automatik | Asas Teknikal: Centralized grease manifold with programmable timer | Faedah Operasi: Memastikan pelinciran galas yang konsisten tanpa campur tangan pengendali | Kesan ROI: Extends bearing life by 2x, preventing catastrophic failures that cost $15,000+ in repairs and lost production

Vibration Isolation Base Frame | Asas Teknikal: Steel coil springs with 95% kecekapan pengasingan | Faedah Operasi: Transmits less than 5 kN of dynamic force to the support structure | Kesan ROI: Eliminates the need for expensive reinforced concrete foundations, penjimatan $20,000 in civil works per installation

Kelebihan Kompetitif



| Metrik Prestasi | Piawaian Industri (Standard Screen) | CE Marked Coke Vibration Screen Distributor | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Kecekapan Saringan (6mm cut) | 7580% | 9295% | +1520% |
| Deck Life (Poliuretana) | 69 bulan | 1824 bulan | +100150% |
| Structural Frame Warranty | 1 tahun | 5 tahun (with FEA certification) | +400% |
| Tahap Bunyi pada 1m | 95 db(A) | 82 db(A) | 14% (safer for operators) |
| Masa Pertukaran (dek) | 4 jam (2man crew) | 45 minit (1man crew) | 81% |
| Penggunaan kuasa (setiap tan) | 0.8 kWj/tan | 0.55 kWj/tan | 31% |

Spesifikasi Teknikal

| Parameter | Spesifikasi |
| : | : |
| Model | CVD2448 (2.4m x 4.8m) |
| Kapasiti | 250 500 Tph (depending on cut point) |
| Number of Decks | 2, 3, atau 4 (boleh dikonfigurasikan) |
| Kawasan Skrin | 11.5 m² setiap dek |
| Vibration Type | Linear Motion |
| Strok | 10 14 mm (boleh laras) |
| Kekerapan getaran | 750 900 Rpm |
| Kuasa motor | 2 x 15 kw (TEFC, IP55) |
| Material of Construction | Strenx 700 plat sisi, AR400 feed box |
| Media Skrin | Poliuretana (slot or square opening) |
| Operating Temperature | 20°C to +80°C (ambien) |
| Berat (lebih kurang) | 12,500 kg |
| Dimensi (L x W x H) | 6.2m x 3.0m x 2.8m |
| CE Certification | ya (DALAM 12100, DALAM 602041) |

Senario Aplikasi

Green Coke Dewatering & Sizing at a Refinery

Cabaran: A Gulf Coast refinery was experiencing 30% downtime on their coke drum dewatering screens due to blinding from 8% kandungan kelembapan. Oversize material was damaging downstream crushers.
Penyelesaian: Installed a 3deck CE Marked Coke Vibration Screen Distributor with slotted polyurethane panels and a 12mm stroke.
Keputusan: Screening efficiency increased to 94%. Crusher wear life doubled. Unplanned downtime dropped from 120 hours/year to 12 jam/tahun, penjimatan $180,000 dalam pengeluaran yang hilang.

Calcined Coke Classification for Anode Production

Cabaran: An aluminum smelter needed a precise 0.5mm to 6mm fraction for anode paste. Their existing screens produced high variability (+/ 1.5mm), causing anode quality issues.
Penyelesaian: Deployed a 4deck unit with a dedicated feed distributor to ensure even material spread.
Keputusan: Particle size distribution tightened to +/ 0.3mm. Anode rejection rate fell from 4% ke 0.5%. The ROI was achieved in 11 months due to reduced scrap and rework costs.

Blast Furnace Coke Screening at a Steel Mill

Cabaran: A steel mill required a consistent +25mm fraction for their blast furnace. Their existing screens were structurally failing after 3 years due to high Gforces.
Penyelesaian: Replaced with a CEcertified unit featuring a heavyduty FEAdesigned frame and 5year structural warranty.
Keputusan: Structural integrity issues eliminated. The +25mm fraction consistency improved to 98%. The plant achieved a 15% pengurangan kadar kok (kg coke per ton of iron) due to better burden permeability.

Pertimbangan Komersial

Peringkat Harga Peralatan (FOB, ExWorks):

• Model Asas (2dek, manual lube): $85,000 $110,000
• Model Standard (3dek, auto lube, poly panels): $135,000 $175,000
• Model Premium (4dek, auto lube, dek yang dipanaskan, pemantauan jarak jauh): $195,000 $250,000

Ciri Pilihan:

• Heated Screen Decks: +$18,000 (for highmoisture applications)
• Ball Tray Cleaning System: +$9,500 (for fine mesh, <3mm)
• Remote Vibration Monitoring System: +$12,000 (penyelenggaraan ramalan)
• Custom Chute Work & Support Steel: +$15,000 $30,000

Pakej Perkhidmatan:

• Waranti Standard: 2 years on mechanical components, 5 years on structural frame.
• Pelan Perkhidmatan Lanjutan (ESP): $8,500/tahun (includes 2 pemeriksaan tahunan, priority parts delivery, 24hour phone support).
• Full Turnkey Installation: $25,000 $45,000 (including commissioning and operator training).

Pilihan Pembiayaan:

• Jaring 30/60 terms untuk pembeli yang layak.
• Leasetoown options starting at $2,800/month for the Standard Model.
• Performancebased payment: 10% upfront, 90% upon achieving 90%+ screening efficiency guarantee.

Soalan Lazim

1. What is the maximum moisture content this screen can handle for green coke?
The standard unit handles up to 12% surface moisture. For moisture levels between 12% dan 18%, we recommend the optional heated deck system to prevent blinding. Di atas 18%, a thermal drying step is advised before screening.

2. How does the CE certification impact my plant’s safety compliance?
The CE mark certifies compliance with the EU Machinery Directive (2006/42/SPR). This includes a full risk assessment, safety circuit design, dan dokumentasi. For plants in regulated jurisdictions, this reduces liability and simplifies safety audits.

3. Can this screen be retrofitted into my existing support structure?
ya. The vibration isolation base frame transmits less than 5 kN of dynamic force. Most existing steel structures rated for 10 kN can support this unit without reinforcement. We provide a free structural load analysis with a purchase order.

4. What is the typical lead time for a custom configuration?
Standard models ship in 810 minggu. Custom configurations (mis., specific deck angles, special materials) require 1216 minggu. We offer expedited production for an additional 15% fee, reducing lead time to 6 minggu.

5. How do I change the cut point for a different product specification?
Cut points are changed by swapping the polyurethane screen panels. A 2man crew can change a full deck in under 45 minit. We stock over 50 standard opening sizes (0.5mm to 100mm) for immediate shipment.

6. What is the expected annual maintenance cost?
Annual maintenance costs average $4,000 $6,000. This includes bearing grease (setiap 40 jam), polyurethane panel replacement (setiap 1824 bulan), and exciter gearbox oil changes (setiap 2,000 jam). The automatic lubrication system reduces labor costs by 60%.

7. Adakah anda menyediakan jaminan prestasi?
ya. We guarantee a minimum screening efficiency of 90% for your specified cut point (based on a representative material sample). If the unit fails to meet this benchmark after commissioning, we will adjust the stroke, sudut, or deck configuration at no cost.