Skrin Getaran Coke: HighCapacity Sizing Solutions for Metallurgical Coke Processing

Cabaran Operasi: When Screen Reliability Becomes Your Bottleneck

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

• Blinding and pegging — Moisture content in quenched coke causes fines to adhere to screen media, reducing effective screening area by up to 40% within a single shift
• Keletihan struktur — The abrasive, highimpact nature of coke handling causes premature failure of screen decks, with typical replacement cycles of 6–9 months under continuous operation
• Kos masa henti — 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
• Kualiti produk tidak konsisten — Offspec coke fractions (bersaiz besar >75mm or undersize <25mm) 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, syif demi syif, without unscheduled interruptions?

Gambaran Keseluruhan Produk: The Coke Vibration Screen

Skrin Getaran Coke adalah tugas berat, linearmotion vibrating screen engineered specifically for the classification of metallurgical coke, kok faundri, and petroleum coke at capacities from 50 ke 400 tph. 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.

Aliran Kerja Operasi

1. Pengagihan Makanan — 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. Stratifikasi — The linear motion (amplitude 6–10mm, frequency 750–900 rpm) menyebabkan zarah yang lebih kecil berhijrah ke bawah melalui dasar bahan, establishing contact with the screen surface
3. Pemisahan Saiz — Material passes over woven wire mesh or polyurethane panels with apertures from 10mm to 80mm, separating into oversize, bersaiz sederhana, dan pecahan bersaiz kecil
4. Pelepasan — 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

Skop Permohonan

This screen is suitable for coke breeze recovery, pemisahan kok kacang (10–25mm), saiz kok foundry (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% kandungan tanah liat.

Ciri Teras

HighG Linear Motion Exciter | Asas Teknikal: Dualshaft counterrotating exciter generating linear vibration at 4.5–5.5 G acceleration | Faedah Operasi: Aggressive stratification separates nearsize particles that typically cause inefficiency in circularmotion screens | Kesan ROI: Screening efficiency improves from industryaverage 85% to 93–95%, reducing recirculation loads by 30%

Sistem Dek Modular | Asas Teknikal: Boltin polyurethane or wire mesh panels with quickrelease tensioning | Faedah Operasi: Your maintenance crew can replace a worn deck section in 45 minit berbanding 4 hours for welded designs | Kesan ROI: Annual maintenance labor savings of $12,000–$18,000 per screen, tambah lagi 15 tambahan waktu operasi setahun

SelfCleaning Ball Decks | Asas Teknikal: Rubber balls in pockets beneath the screening surface, diaktifkan oleh getaran skrin | Faedah Operasi: Continuous aperture clearing prevents blinding from moist coke fines, maintaining effective open area above 85% | Kesan ROI: Eliminates manual cleaning stops, recovering 2–3 hours of production per week

Rangka Struktur Tugas Berat | Asas Teknikal: S355J2 steel side plates (minimum 12mm thickness) with stressrelieved welded construction and finite element analysis validation | Faedah Operasi: Hayat perkhidmatan bingkai melebihi 15 years under continuous 24/7 operasi, even with impact loading from feed chutes | Kesan ROI: Replacement cost avoidance of $45,000–$60,000 per screen over a decade

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

Penahanan Habuk Bersepadu | Asas Teknikal: Bolted dust covers with rubber seals and optional negativepressure extraction ports | Faedah Operasi: Meets EPA particulate emission standards (PM10 < 50 mg/m³) without external enclosure costs | Kesan ROI: Avoids $25,000–$40,000 in separate dust collection hood fabrication and installation

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

Kelebihan Kompetitif

| Metrik Prestasi | Piawaian Industri | Penyelesaian Skrin Getaran Coke | Kelebihan (% Penambahbaikan) |
|||||
| Kecekapan Saringan (at 50mm cut point) | 85–88% | 93–95% | 6–8% lebih tinggi |
| Deck Replacement Time | 4–6 hours | 45–90 minutes | 60–75% faster |
| Frame Service Life | 8–10 years | 15+ tahun | 50% lebih lama |
| Masa Henti Tidak Berjadual (tahunan) | 120–180 hours | 40–60 hours | 60– Pengurangan 70%. |
| Effective Open Area (after 8h operation) | 55–65% | 85–90% | 30–40% better |
| Tahap Bunyi pada 1m | 95–100 dB(A) | 85–88 dB(A) | 10–12 dB(A) lebih rendah |
| Penggunaan Tenaga setiap Tan Diproses | 0.35–0.45 kWh/t | 0.25–0.30 kWh/t | 20–30% less |

Spesifikasi Teknikal

| Parameter | Spesifikasi |
|||
| Julat Model | CVS15 (15 m²), CVS20 (20 m²), CVS25 (25 m²) |
| Julat Kapasiti | 50–150 tph (CVS15), 100–250 tph (CVS20), 150–400 tph (CVS25) |
| Julat Titik Potong | 10–80 mm (adjustable via deck configuration) |
| Konfigurasi Dek Skrin | 1, 2, atau 3 dek (depending on fraction requirements) |
| Kekerapan getaran | 750–900 rpm (boleh laras melalui VFD) |
| Amplitud (Strok) | 6-10 mm (boleh laras) |
| Pecutan | 4.5–5.5 G |
| Screen Inclination | 0° to 15° (boleh laras) |
| Kuasa motor | 2 × 15 kw (CVS15), 2 × 22 kw (CVS20), 2 × 30 kw (CVS25) |
| Voltan | 380V / 660V / 3fasa / 50Hz atau 60Hz (custom available) |
| Bahan Plat Sisi | Keluli struktur S355J2, 12–16mm thickness |
| Pilihan Media Skrin | Woven wire mesh (mild steel or stainless), panel poliuretana (80 Pantai A), panel getah |
| Saiz suapan (maksimum) | 150 mm |
| Feed Temperature (maksimum) | 120°C continuous |
| Kelembapan Suapan (maksimum) | 12% (quenched coke) |
| Dimensi Keseluruhan (CVS20) | 6.5m L × 3.2m W × 2.8m H |
| Jumlah Berat (CVS20) | 18,500 kg |
| Julat Suhu Operasi | 10°C hingga +50°C (ambien) |
| Pelepasan Habuk (with covers) | PM10 < 50 mg/m³ |
| Tahap Bunyi pada 1m | 85–88 dB(A) |
| Vibration Isolation Efficiency | 95% |

Senario Aplikasi

Integrated Steel Plant — Blast Furnace Coke Sizing | Cabaran: A 2.8 MTPA steel plant experienced 14% offspec coke (bersaiz besar >75mm) reaching the blast furnace, causing burden distribution problems and increasing coke rate by 18 kg/tHM | Penyelesaian: Installation of two CVS20 screens in parallel, configured with 75mm top deck and 25mm bottom deck, pemprosesan 220 tph masing2 | Keputusan: Offspec coke reduced to 3.5%, kadar kok menurun sebanyak 12 kg/tHM, penjimatan kos bahan api tahunan sebanyak $2.1 juta, screen availability maintained at 96.5% berakhir 18 bulan

Foundry Coke Producer — Nut Coke Recovery | Cabaran: A foundry coke producer was discarding 8,000 tpy of 10–25mm nut coke as waste due to inefficient screening, mewakili $640,000 in lost revenue annually | Penyelesaian: Implementation of a CVS15 screen with polyurethane panels (10mm and 25mm apertures) and ball deck cleaning system | Keputusan: Nut coke recovery increased to 92% of available material, menjana $590,000 in new revenue in the first year, tempoh bayaran balik sebanyak 7 bulan

Coke Breeze Processing — Sinter Plant Feed | Cabaran: A sinter plant required consistent 0–6mm coke breeze at 85 tph, but existing screens delivered only 68 tph with frequent blinding from 9% kandungan kelembapan | Penyelesaian: Deployment of a CVS15 screen with 6mm stainless wire mesh and highG exciter (5.2 G) to overcome moisture adhesion | Keputusan: Throughput meningkat kepada 82 tph (20% penambahbaikan), moisturerelated downtime reduced from 14 jam/bulan ke 2 jam/bulan, sinter plant productivity improved by 4.5%

Pertimbangan Komersial

Peringkat Harga

| Konfigurasi | Julat Harga (USD) | Target Application |
||||
| Standard (CVS15, dek tunggal, Wire mesh) | $85,000–$110,000 | Basic coke breeze screening |
| Dipertingkatkan (CVS20, dual deck, panel poliuretana, penutup habuk) | $145,000–$185,000 | Klasifikasi kok relau letupan |
| Premium (CVS25, triple deck, full dust containment, Kawalan VFD, pemantauan jarak jauh) | $220,000–$280,000 | Highcapacity integrated steel plants |

Ciri Pilihan

• Pakej Kawalan VFD ($8,500–$12,000) — Enables frequency adjustment for variable feed conditions
• Sistem Pemantauan Jauh ($6,000–$9,000) — Realtime vibration, suhu, and bearing health data via Modbus or Profibus
• CeramicLined Feed Box ($4,500–$7,000) — Extends wear life in highimpact feed zones by 3×
• Kit Alat Ganti ($12,000–$18,000) — Includes exciter bearings, anjing laut, panel skrin, and tensioning hardware for 12 bulan beroperasi

Pakej Perkhidmatan

| Pakej | Liputan | Kos Tahunan (USD) |
||||
| asas | 2 lawatan penyelenggaraan pencegahan, sokongan telefon, 48penghantaran bahagian jam | $9,500 |
| Standard | 4 lawatan penyelenggaraan pencegahan, onsite repair within 24 jam, penghantaran bahagian keutamaan, audit prestasi tahunan | $18,000 |
| Komprehensif | Unlimited technical support, 12respons di tapak jam, full parts inventory management, pengoptimuman prestasi suku tahunan | $32,000 |

Pilihan Pembiayaan

• Pajakan Operasi — 36–60 month terms with option to purchase at fair market value; bayaran bulanan daripada $2,400
• Pembiayaan Peralatan — 10–20% down payment, kadar tetap daripada 6.5% APR, terms up to 84 bulan
• Kontrak Berasaskan Prestasi — Payperton processed with minimum throughput guarantee; ideal for contractors with variable production volumes

Soalan Lazim

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

A: ya. 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. Walau bagaimanapun, 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?

A: 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% surcaj.

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

A: Data medan daripada 14 installations shows that screening efficiency remains above 90% for moisture content up to 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% untuk prestasi optimum. For consistently higher moisture, consider a predrying step or heated screen option.

Q: What maintenance intervals should we plan for?

A: Under continuous 24/7 operasi, the following schedule applies: exciter bearing inspection every 2,000 jam (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?

A: ya. 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: Apakah perlindungan waranti yang disediakan?

A: The standard warranty covers 24 bulan dari pentauliahan atau 30 bulan dari penghantaran, yang mana berlaku dahulu. Coverage includes exciter assembly, plat sisi, cross members, and vibration isolators. Screen panels and wear liners are excluded as consumable items. Pilihan jaminan lanjutan tersedia sehingga 60 months through the Comprehensive service package.

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

A: 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. Untuk pemprosesan tumbuhan 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?

A: 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.