1. PEMBUKAAN PAINPOINT DRIVEN

Is your petroleum coke processing operation struggling with inconsistent product quality and excessive maintenance costs? The screening phase for Chinese coke is a critical bottleneck where common failures directly impact profitability. Adakah anda menghadapi:
High Fines Carryover: Ineffective screening allows excessive fines into the finished product, degrading market value and risking customer rejection.
Premature Screen Clogging & Membutakan: The abrasive, often moist nature of delayed coke leads to rapid mesh blockage, requiring frequent, costly downtime for manual cleaning or panel replacement.
Excessive Equipment Wear: Standard screen decks and exciters fail under the continuous abrasion of coke particles, leading to unplanned breakdowns and high spare part consumption.
Inconsistent Throughput: Inefficient vibration transmission and poor material flow result in uneven bed depth, limiting capacity and creating a process bottleneck.
Kos Operasi yang Tinggi: The cumulative effect of downtime, maintenance labor, part replacements, and energy waste erodes your plant's operational margin.

The central question for plant managers is: how can you achieve precise particle separation for Chinese coke while maximizing uptime and minimizing total cost of ownership?

2. GAMBARAN KESELURUHAN PRODUK

The Chinese Coke Vibration Screen Processing Plant is a heavyduty, highamplitude screening system engineered specifically for the dry or slightly moist classification of petroleum coke (petcoke). It is designed to separate green or calcined coke into precise fractions (mis., ketulan, nut, chip) at high tonnage rates.

Aliran Kerja Operasi:
1. Pengenalan suapan: Raw or crushed coke is uniformly fed onto the robust feed box of the vibration screen.
2. HighIntensity Stratification: A powerful dualvibrator motor system drives a linear or elliptical motion, aggressively stratifying the material bed to bring fines into contact with the screen mesh.
3. Precise Size Separation: Sized fractions pass through designated screen deck apertures (via multiple deck configurations), while oversize material conveys to the discharge end.
4. Efficient Discharge: Separated fractions are discharged via dedicated chutes into distinct collection hoppers or conveyors for downstream processing or storage.

Skop Permohonan & Batasan:
Skop: Ideal for dry screening of green delayed coke and calcined petroleum coke in sizing applications from ~50mm down to ~0.5mm. Suitable for fixed plant installations in refineries, anode plants, and electrode material production facilities.
Batasan: Not designed as a dewatering screen for slurry applications. Optimal performance assumes controlled feed moisture; excessively sticky or wet feed may require predrying or specialized screen surface treatments.

3. CIRI TERAS

HeavyDuty Deck Construction | Asas Teknikal: Modular, reinforced frame with replaceable wear liners | Faedah Operasi: Withstands extreme abrasion from coke particles, extending structural life by over 60% compared to standard designs | Kesan ROI: Reduces capital expenditure on full deck replacements, lowering longterm depreciation cost per ton.

AntiBlinding Screen Mesh Systems | Asas Teknikal: Tensioned polyurethane or rubberclad wire panels with flexible cleaning balls/rings | Faedah Operasi: Selfcleaning action prevents aperture blockage from nearsize particles and moisture | Kesan ROI: Menghapuskan 23 hours of daily downtime for manual rodding, increasing annual available production time.

Dual CounterRotating Vibrator Motors | Asas Teknikal: Synchronized motors generating a linear force vector; lubricatedforlife bearings | Faedah Operasi: Delivers consistent, highGforce screening action with minimal maintenance; failure of one motor allows continued reducedcapacity operation | Kesan ROI: Cuts vibration drive maintenance costs by up to 40% and provides operational redundancy.

HuckBolted Side Plate Assembly | Asas Teknikal: Aircraftgrade hightensile fastening system | Faedah Operasi: Creates a rigid, monolithic frame that eliminates weld fatigue failures common in highvibration environments | Kesan ROI: Virtually eliminates unscheduled downtime from cracked side plates, a common failure point in coke screening.

Pemacu Frekuensi Boleh Ubah (VFD) Kawalan | Asas Teknikal: Integrated inverter allows precise adjustment of vibrator motor speed (Rpm) | Faedah Operasi: Operators can finetune amplitude and stroke dynamically to match feed rate and material characteristics (mis., moisture variance) | Kesan ROI: Optimizes efficiency for varying feedstock conditions without mechanical changes, ensuring peak separation efficiency.

Enclosed Dust Containment Design | Asas Teknikal: Sealed covers with inspection hatches and dust extraction ports | Faedah Operasi: Significantly reduces airborne particulate emissions at transfer points, improving plant environmental compliance and worker safety | Kesan ROI: Lowers cost associated with dust collection system load and mitigates regulatory noncompliance risks.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penyelesaian Standard Industri | Chinese Coke Vibration Screen Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Screen Panel Lifespan (Abrasive Coke) | Standard Steel Wire Mesh 68 minggu| Reinforced Polyurethane Panels 2024 minggu| +200% ke +250% |
| Kecekapan Saringan (Fines Removal) ~4mm cut| ~8590% Efficiency| Konsisten >95% Kecekapan| +5 ke +10 mata peratusan |
| Annual Unscheduled Downtime (Peringkat Saringan)| 120150 hours/year| 16,000 waktu operasi (L10 life)| +100% |

5. SPESIFIKASI TEKNIKAL

Model Capacity Range: daripada 50 TPH berakhir 800 TPH depending on model size and deck configuration.
Screen Deck Configuration: Bujang, berganda, or tripledeck options; standard sizes from 1.2m x 3m up to 2.4m x 6m.
Sistem pemacu: Two externally mounted vibrator motors; power range from 7.5 kW kepada 30 kW per motor depending on machine size.
Screen Surface Options: Hightension woven wire cloths; polyurethane modular panels; rubberclad panels; various aperture shapes/sizes.
Bahan Binaan: Mainframe carbon steel Q235B/Q345B; Wear liners AR400 abrasionresistant steel; Contact parts customizable with stainless steel where required.
Operating Environment Range: Ambient temperature from 20°C to +45°C; designed for dustladen atmospheres up to IP65 protection level on motors.
Dimensi Fizikal & Berat: Berbeza dengan ketara mengikut model; largest models may require sectionalized fabrication for site assembly.

6. SENARIO APLIKASI

Anode Grade Calcined Coke Production Plant

Cabaran: A major electrode manufacturer needed consistent removal of 4mm fines from calcined coke to meet strict anode paste specifications but faced rapid blinding of traditional screens every shift.
Penyelesaian: Implementation of a tripledeck Chinese Coke Vibration Screen equipped with nonblinding polyurethane panels on the top two decks and finewire tensioned cloth on the bottom deck.
Keputusan: Screening efficiency for 4mm material stabilized at 96%. Manual cleaning intervals extended from every 8 hours to once per week. This resulted in a quantified increase of 12% in onspec product yield within the first quarter.

Green Delayed Coke Sizing at Refinery

Cabaran: A refinery's existing screens suffered from chronic side plate weld fractures due to highcycle fatigue when processing dense green delayed coke lumps (~150mm), causing monthly stoppages.
Penyelesaian: Installation of two heavyduty linear motion screens featuring Huckbolted side plate construction and extraheavyduty coil spring isolators.
Keputusan: Field data shows zero structural failures after 18 months of continuous operation. Annual maintenance costs for the screening station decreased by an estimated $65k USD due eliminated repair work and lost production.

7. PERTIMBANGAN KOMERSIL

Our Chinese Coke Vibration Screens are offered across three primary tiers:

1. Siri Tugas Standard ($): For lowercapacity requirements (<150 Tph) or less severe duty cycles using proven standard components.
2. HeavyDuty Performance Series ($$): The recommended tier for most petcoke applications featuring all core features listed above as standard (Huckbolts,VFDready drives).
3. Premium Customized Series ($$$): For maximum uptime criticality including full stainless steel contact surfaces advanced condition monitoring sensors integrated spray systems etc

Optional Features include:
Automated lubrication systems
Integrated temperature/vibration sensors
Specialized wear coatings
Custom discharge hoods chutes

Service Packages range from basic commissioning support through comprehensive annual maintenance contracts including guaranteed spare parts availability

Financing Options are available including equipment leasing capital expenditure financing solutions tailored project finance

Soalan Lazim

Q1 How do I determine if this screen is compatible with my existing feed conveyor discharge height?
A1 Our technical specifications include detailed dimensional drawings including inlet outlet heights We require your current layout drawings provide integration analysis ensure seamless retrofit

Q2 What is typical installation timeline commissioning process?
A2 For standard models delivery is typically weeks following order Installation commissioning supervised by our engineers usually requires days depending foundation readiness We provide detailed foundation boltloading diagrams advance

Q3 Can this screen handle variations feedstock moisture content?
A3 Yes The combination antiblinding panels variable frequency drive control allows operators adjust performance cope moderate moisture increases However sustained processing sticky wet material outside design parameters will reduce efficiency Predrying recommended such cases

Q4 What are ongoing operational costs expected be?
A4 Primary costs are electricity periodic screen panel replacement energy consumption optimized through efficient drive design Panel lifespan varies based material but our heavyduty designs typically operate months between changes reducing both part cost labor downtime

Q5 Do you offer performance guarantees?
A5 Yes We provide guaranteed capacity throughput based your specific feedstock analysis written guarantee covering screening efficiency key performance metrics as part commercial agreement

Q6 Are spare parts readily available?
A6 We maintain strategic inventory critical wear parts vibrator motors ensure fast dispatch Additionally we provide lifecycle planning recommending optimal spare parts kit minimize your inventory carrying costs while ensuring operational security