Menyasarkan Pengurus Loji, Pakar Perolehan & Kontraktor Kejuruteraan: Optimize Your Coke Sizing & Classification with Advanced Vibration Screen Technology

1. Addressing Critical Operational Challenges in Coke Handling

Is your coke screening process a source of inefficiency and unexpected cost? For operations dependent on consistent coke quality for blast furnace feed, foundry operations, or anode production, subpar screening directly impacts downstream performance and profitability. Titik kesakitan biasa termasuk:
Penjanaan Denda Berlebihan & Product Degradation: Conventional screens with highimpact loading can fracture coke, increasing the percentage of undersize material (10mm/6mm) and reducing the yield of valuable lump product. This represents direct revenue loss.
Frequent Downtime for Screen Cloth Changes: Blinding and pegging of screen meshes by moist or sticky coke halts production. Industry data indicates average downtime for screen maintenance can exceed 15 hours per month per line.
Penggunaan Tenaga Tinggi & Keletihan Struktur: Inefficient vibratory motion requires more power to move material, while excessive vibration transmission to support structures leads to premature wear and potential foundation issues.
Saiz Tidak Konsisten & Pencemaran: Inaccurate separation results in oversized fines entering the lump stream or valuable lump coke being lost to the fines conveyor, compromising product specifications and customer contracts.
Harsh Environmental Working Conditions: Dust emission at transfer points and high noise levels create noncompliance risks and operator health concerns.

Are you evaluating solutions to reduce total cost of ownership, extend mean time between failures (MTBF), and protect your premium coke product integrity?

2. Gambaran Keseluruhan Produk: HeavyDuty EcoFriendly Coke Vibration Screens

Our engineered line of EcoFriendly Coke Vibration Screens is designed for highcapacity sizing (scalping, penggredan) of metallurgical (bertemu) Coke, kok petroleum (petcoke), dan kok faundri. These screens prioritize material preservation while maximizing throughput and operational cleanliness.

Aliran Kerja Operasi:
1. Suapan Terkawal: Coke is fed onto the screen via a controlledrate feeder, minimizing impact load on the screen cloth.
2. Stratifikasi yang cekap & Perpisahan: A combination of precise vibratory motion and optimized deck layout stratifies material, allowing accurately sized particles to pass through the screen media.
3. Clean Discharge: Sized fractions (mis., ketulan, nut, angin sepoi-sepoi) are discharged into separate chutes with minimal intermixing for downstream processing or loading.

Skop Permohonan: Primary and secondary screening of dry or slightly moist coke in battery discharge stations, crushing plant circuits, and loadout facilities. Ideal apertures from 4mm to 80mm.

Batasan: Not designed as a dewatering screen for slurry applications or for handling highly adhesive materials without specialized screen media.

3. Ciri Teras: Direka bentuk untuk prestasi & ROI

Our design philosophy focuses on measurable improvements in reliability and efficiency.

Modular Polyurethane Screen Decks | Asas Teknikal: Abrasionresistant elastomer with openarea optimization | Faedah Operasi: Reduces blinding by up to 60% compared to steel wire cloth; dampens noise by approximately 810 dBA; allows for faster panel changeout | Kesan ROI: Cuts maintenance downtime by an estimated 40% and extends media life by 35x.

DustEncapsulated Deck Design | Asas Teknikal: Integrated skirt boards and sealed discharge hoods with dust extraction ports | Faedah Operasi: Contains dust at critical transfer points, reducing airborne particulate matter | Kesan ROI: Lowers housekeeping costs and facilitates compliance with site environmental regulations.

Pemacu Frekuensi Pembolehubah (VFD) Sistem kawalan | Asas Teknikal: Precision control of vibratory motor speed/amplitude | Faedah Operasi: Operators can finetune screening action for varying feed rates or moisture content to optimize efficiency; keupayaan softstart mengurangkan tekanan mekanikal | Kesan ROI: Mencapai sehingga 20% energy savings versus fixedspeed drives; extends bearing life.

LowNoise Vibrator Assemblies | Asas Teknikal: Enclosed geartype vibrators with highgrade lubricants and precision bearings | Faedah Operasi: Provides consistent linear or elliptical motion with sound levels consistently below 85 db(A) di 1 meter | Kesan ROI: Creates a safer operator environment, reducing hearing protection requirements.

Base Frame Vibration Isolation | Asas Teknikal: Highperformance rubber or spring isolators between the screen body and support structure | Faedah Operasi: Absorbs up to 95% daripada beban dinamik, preventing transmission to the building structure | Kesan ROI: Eliminates costly structural reinforcement needs and prevents vibrationinduced fatigue failures in surrounding equipment.

4. Kelebihan Kompetitif: Metrik Prestasi Boleh Dikira

| Metrik Prestasi | Cabaran Standard Industri | Our EcoFriendly Coke Vibration Screen Solution | Kelebihan Berdokumen |
| : | : | : | : |
| Screen Media Lifespan (Coke yang kasar) | Steel Wire Cloth: 23 berbulan-bulan | Modular Polyurethane Panels | +300% ke +500% Penambahbaikan |
| Penggunaan Tenaga setiap Tan Disaring| FixedSpeed Drives at Constant Load| VFDOptimized Operation| Hingga 20% Pengurangan |
| Masa Henti Penyelenggaraan Tahunan| ~180 hours (estimates for cloth changes/bearing service)| ~108 hours (diunjurkan)| Hingga 40% Pengurangan |
| NearScreen Noise Emission| Selalunya >90 db(A)| Engineered 5 db(A) Pengurangan |

5. Spesifikasi Teknikal

Julat Model & Kapasiti: Sizes from 1.2m x 3.0m single deck to 2.4m x 6.0m triple deck configurations; kapasiti daripada 50 TPH berakhir 800 TPH bergantung pada saiz apertur dan ciri bahan.
Keperluan kuasa: Driven by twin outofbalance vibrator motors ranging from 7.5 kW kepada 30 kW per motor, dibekalkan untuk voltan global (380V480V / 5060Hz).
Spesifikasi Bahan: Deck frames constructed from abrasionresistant steel (Standard pelapik AR400); side plates from mild steel; polyurethane media in multiple compound grades for specific abrasion/impact profiles.
Dimensi Fizikal: Varied by model; emphasis on low headroom design for easier installation in existing buildings.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; IP65 protection standard on vibrator motors; suitable for outdoor installation with optional weather covers.

6.Senario Aplikasi

[Integrated Steel Mill Blast Furnace Feed] Cabaran: A major mill experienced excessive fines generation (10mm) at their battery screening station, losing premium lump coke (>25mm) yield due to aggressive screening action. Frequent wire mesh failures caused biweekly stoppages.Penyelesaian: Installation of two large singledeck EcoFriendly Coke Vibration Screens with polyurethane panels sized at a nominal25mm aperture.Keputusan: Fines generation reduced by18%; screen panel replacement interval extended from2 weeksto9 months; annualized yield increase valued against lump premium pricing.

[Petroleum Coke Calcining Plant Product Grading] Cabaran: A calciner needed precise separation of calcined petcoke into3 fractions (+25mm,25/+12mm,12mm) but struggled with dust emission at open transfer pointsand rapid cloth wearfrom abrasive material.Penyelesaian: Implementationof a tripledeck enclosedscreenwith our dustencapsulated designand specialized polyurethane screenshapes.Keputusan: Dust emissionsatthescreenhouse measured below required permit levels;media lifespan increasedby400%;product segregation accuracy improvedto98%.

7.Pertimbangan Komersial

Peringkat Harga:
Siri Standard: Robust base modelsfor standardduty cyclesand environments.
Siri Kapasiti Tinggi: Reinforced designsfor throughputs exceeding600TPHwithpremium components.
Modular Upgrade Kits: Retrofittable packages(ex.VFDkits,dust hoods)for existing equipment upgrades.

Ciri Pilihan:
Heated deckscreensformoisture mitigationin humid climates.
Different typesofscreenmedia(perforated plate,getah,poliuretana)
Penderia pemantauan keadaan lanjutan(getaran,suhu)onvibrator bearings.
Laluan pejalan kaki,tangga,and safety guarding packages.

Pakej Perkhidmatan:
Extended warrantyoptions(sehingga 36 bulan).
Annual inspectionand vibration analysis contracts.
Onsite trainingfor operationand preventive maintenance.

Pilihan Pembiayaan: Flexible commercial leasingstructuresandrentaltoownprogramsare availableto spread capital expenditure.

8.Soalan Lazim(Soalan Lazim)

S1:What isthe lead timefora typicalcoke vibrationscreen unit?
A1:Builttimes varybycomplexity,butstandardmodelsare typicallyavailablewithin1216weeksfromorderconfirmation.Longleaditemslikecustommotorsare identifiedearlyintheprocess.

S2:Canyourscreensbe integratedintoourexistingPLCcontrol system?
A2:TheVariableFrequencyDrive(VFD)control systemcomesstandardwithindustrystandardcommunicationprotocols(ProfibusDP,Ethernet/IP).Our engineerswill provideall necessary documentationfor integrationbyyour controls team.

S3:Whatisthe expectedoperational lifespanofthisequipment?
A3:Thecore structureisdesigned fora minimumservice lifeof15+yearsundernormaloperatingconditions.Criticalwearcomponentslikescreenmediaandvibrator bearingshave definedlifespansbasedonoperatinghours,keterlaluan bahan,andmaintenance scheduleswhichwe outlineinour manuals.

S4:Doyouofferperformance guarantees?
A4:A throughputandefficiency guaranteeisprovidedbasedonagreeduponfeedmaterialanalysisandspecifications.Guaranteescover separation accuracyandratedcapacityunder defined conditions.

S5:Whatlevelofsparesinventoryshouldwemaintainonsite?
A5:A recommendedspareslistforthe firsttwoyearsofoperationisprovided.Thisfocusesoncriticalwearitemsandspecificcomponentsthatmayhave longerprocurement times.We adviseholdingbasic gaskets,sets offasteners,andone setofscreenpanelsperunitonsite.

S6:Isthe polyurethanemedia compatiblewithhotcoke?
A6:Specifichightemperaturepolyurethanecompoundsare availableforservice where feedtemperaturesconsistentlyexceed80°C.We will specifythe correctmaterial gradebasedonyour operatingdata duringthe quotation process.

S7:Whatkindoffoundation preparationisrequired?
A7:Due tothereduced dynamicforcesfromour isolation system,foudnation requirementsare lessrigorousthanforconventional screens.Detailedstaticanddynamicload drawingsare suppliedforall modelsforsubmissiontoyour civil engineeringteam