1. PEMBUKAAN PAINPOINT DRIVEN

Are your coke screening operations plagued by persistent, ketidakcekapan yang mahal? Plant managers and engineering contractors face significant challenges in maintaining consistent product quality and throughput. Titik kesakitan biasa termasuk:
Membutakan & Pemindahan: Moisture and fine particles adhere to screen decks, blinding apertures and forcing material carryover. Ini menghasilkan produk offspec, peningkatan beban rerushing, and wasted yield.
Excessive Downtime & Penyelenggaraan: Frequent screen cloth changes and structural repairs due to aggressive vibration or material abrasion halt your production line, secara langsung memberi kesan kepada keuntungan anda.
Saiz Tidak Konsisten & Kerugian Hasil: Ineffective screening leads to missized coke fractions, compromising blast furnace efficiency for your customers and eroding your profit margins.
Kos Operasi yang Tinggi: Kegagalan komponen pramatang, penggunaan tenaga yang tinggi daripada pemacu yang tidak cekap, and laborintensive cleaning procedures inflate your costperton.

Is there a screening solution engineered to withstand the abrasive nature of metallurgical coke while delivering precise separation with maximum uptime?

2. GAMBARAN KESELURUHAN PRODUK

The ISOCertified Coke Vibration Screen is a heavyduty linear or elliptical motion vibrating screen specifically engineered for the dry separation of metallurgical coke into precise size fractions (mis., kok relau letupan, kacang kok, angin sepoi-sepoi). Its robust design addresses the unique abrasiveness, ketumpatan, and size range of coke particles.

Aliran Kerja Operasi:
1. Suapan & Pengedaran: Sized coke from crushers is evenly distributed across the full width of the screen’s feed box.
2. Stratifikasi & Perpisahan: HighGforce vibration stratifies material; fines pass through the configured screen cloth apertures while oversize travels toward the discharge end.
3. Pelepasan: Correctly sized fractions are discharged into separate chutes or conveyors for stockpiling or shipment.

Skop Permohonan: Primary and secondary screening of metallurgical coke in coke plants, kilang keluli, dan terminal pengendalian pukal. Ideal for sizing ranges from 80mm down to 05mm breeze.

Batasan: Not designed for wet screening applications or for materials with extreme temperature (>150°C) without specific modifications.

3. CIRI TERAS

Sistem Sokongan Dek Tugas Berat | Asas Teknikal: Reinforced crossmembers with rubber buffer pads | Faedah Operasi: Eliminates direct metaltometal contact, drastically reducing noise (<85db) and dissipating destructive harmonic vibrations | Kesan ROI: Extends screen cloth and structural life by up to 40%, reducing part replacement costs and downtime.

Modular Polyurethane Screen Panels | Asas Teknikal: Abrasionresistant PU with reinforced steel backing | Faedah Operasi: Highly resistant to wear from sharp coke edges; antiblinding properties reduce pegging | Kesan ROI: Panel service life is 35x longer than wire mesh, lowering consumable inventory costs and changeout labor.

DualVibration Motor Drive System | Asas Teknikal: Two synchronized externally mounted motors generating linear motion | Faedah Operasi: Simplified maintenance; no complex gearboxes or driveshafts; pelarasan mudah amplitud | Kesan ROI: Proven motor reliability reduces drive system failures; energyefficient design cuts power consumption per ton screened.

Total Enclosure Dust Containment Skirt | Asas Teknikal: Multistage rubber sealing system around deck perimeter | Faedah Operasi: Effectively contains coke dust at transfer points, meningkatkan keselamatan tapak dan pematuhan alam sekitar | Kesan ROI: Minimizes material loss as product dust and reduces housekeeping labor requirements.

QuickRelease Tensioning System for Screen Cloths | Asas Teknikal: Lateral tensioning rails with simple bolt mechanisms | Faedah Operasi: Enables singleoperator screen panel change in under 30 minutes versus industrystandard hours | Kesan ROI: Directly increases plant availability by minimizing planned maintenance windows.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Typical Coke Screen) | ISOCertified Coke Vibration Screen Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Kehidupan Kain Skrin | 23 months with wire mesh panels | 812 months with modular PU panels | +300% hayat perkhidmatan |
| Ketersediaan Tahunan| ~92% (700+ jam henti) | >96% (<350 jam henti) | +4% absolute availability |
| Sizing Accuracy| ~9092% efficiency (varies with moisture)| >95% consistent efficiency (antiblinding design) | +35% keuntungan kecekapan |
| Noise Emission| Selalunya melebihi 90 db(A) di 1 meter| Mengekalkan <85 db(A) di 1 meter| Pengurangan ketara dalam pendedahan bunyi |
| Penggunaan tenaga| Baseline per ton processed| Hingga 15% kWj/tan lebih rendah (optimized drive/mass)| 15% kos operasi |

5. SPESIFIKASI TEKNIKAL

Julat Model & Kapasiti: Tersedia dalam lebar dari 1.2m hingga 3.6m; panjang dari 4.8m hingga 10m. Kapasiti daripada 200 ke atas 1500 Ton metrik sejam, depending on aperture size and feed gradation.
Keperluan kuasa: Motor getaran dwi terdiri daripada 2 x 7.5 kW kepada 2 x 45 kw (400V/50Hz atau seperti yang dinyatakan). Total installed power depends on machine size and mass.
Spesifikasi Bahan: Bingkai utama: Keluli struktur S355JR. Bingkai dek: Hardox® wear plate or equivalent on critical areas. Screen panels: Customizable polyurethane or rubber compounds for required cut point.
Dimensi Fizikal & Mass: Berbeza dengan ketara mengikut model. Contoh (Medium Duty): Width=2.4m, Length=6m; Approximate Mass=8,500 kg excluding motors.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Bearings rated for continuous operation up to +120°C surface temperature.

6. SENARIO APLIKASI

[Integrated Steel Plant] Cabaran: A major steel producer faced consistent yield loss due to fine coke (<10mm) contaminating blast furnacegrade fraction (+25mm). Manual cleaning of blinded wire mesh screens was required weekly.

[Pengeluar Coke Saudagar] Cabaran: A merchant plant needed to increase throughput after a crusher upgrade but was bottlenecked by an older screening stage that could not handle the increased load without excessive carryover.

[Penyelesaian:] Implementation of a primaryclassifying ISOCertified Coke Vibration Screen fitted with multislope PU panels on the top deck.

[Keputusan:] Sizing accuracy improved from ~88% to over 96%. Blindingrelated stoppages were eliminated.

[Penyelesaian:] Installation of two widebody linear motion screens in parallel for load distribution.

[Keputusan:] Screening capacity matched crusher output at over 800 tph per line.

7. PERTIMBANGAN KOMERSIL

Our ISOCertified Coke Vibration Screens are offered in three primary tiers:

Peringkat Kewajipan Standard: Untuk talian kapasiti yang lebih rendah (<400 tph), featuring robust construction with standard wear liners.
Peringkat Tugas Berat (Paling Biasa): Termasuk semua ciri teras yang disenaraikan di atas (PU panels, quickrelease systems), designed for mainline primary/secondary screening.
Peringkat Premium: Includes full instrumentation (penderia pemantauan getaran), sistem pelinciran automatik, and special coatings for highly corrosive environments.

Optional features include stainless steel components for specific zones, custom feed boxes/hoppers, spray bar systems for controlled dust suppression during transfer.

We offer comprehensive service packages ranging from annual inspections with condition reports to full longterm maintenance agreements including parts supply.

Flexible financing options are available through our partners including equipment leasing programs tailored for capital expenditure cycles common in mineral processing industries.

8.Soalan Lazim

Q1 – Are these screens compatible with our existing feed conveyor discharge heights?
A1 – Our engineering team designs each unit based on your specific layout data provided during quotation including feed height clearances ensuring seamless integration into your current flow sheet without major structural modifications required onsite

Q2 – What is the expected operational impact during installation?
A2 – We provide detailed installation plans requiring typically a fivetosevenday shutdown window depending on foundation preparation requirements performed beforehand by your team

Q3 – How does this solution handle variations in feed moisture content?
A3 – The combination of high Gforce vibration antiblinding panel technology allows effective stratification even with moderate surface moisture Field data shows consistent performance upto four percent surface moisture beyond which predrying is recommended

Q4 – What are typical commercial terms lead time payment structure?
A4 – Standard lead times range between twelvesixteen weeks exworks Payment terms are generally structured as thirty percent upon order sixtyfive percent before shipment five percent after commissioning

Q5 – Do you provide performance guarantees?
A5 – Yes we guarantee mechanical performance against agreed specifications including capacity sizing accuracy under defined feed conditions These are detailed within our commercial proposal

Q6 – Who handles installation supervision commissioning?
A6 – We offer optional expert site supervision commissioning services as part of our technical package ensuring optimal startup performance knowledge transfer directly onto your operating maintenance teams

Q7 – Can we retrofit certain features like quickrelease tensioning onto our existing screens?
A7 – In many cases yes Our service division conducts audits provides retrofit kits modernize older equipment extending its life improving maintainability often providing strong returnoninvestment versus complete replacement