Rohs Compliant Coke Vibration Screen
RoHS Compliant Coke Vibration Screen: Precision Screening for Metallurgical Coke Processing
The Hidden Costs of NonCompliant Coke Screening
Every ton of undersized coke fines that bypasses your screening system represents lost revenue—typically $15–$25 per ton in reprocessing or disposal fees. Plant managers report that conventional vibrating screens handling metallurgical coke experience 12–18% unscheduled downtime annually due to structural fatigue from abrasive coke particles. Engineering contractors face increasing pressure to specify equipment meeting RoHS (Sekatan Bahan Berbahaya) directives for Europeanbound steel exports, yet many screening solutions still contain restricted materials in their electrical components and weld alloys.
Your operators deal with blinding and pegging issues that reduce effective screening area by 30–40% within six months of operation. Persoalannya menjadi: Can your current screening equipment maintain consistent cutpoint accuracy below 6mm while meeting environmental compliance standards? Or are you accepting reduced throughput and increased maintenance intervals as unavoidable costs of coke processing?
Gambaran Keseluruhan Produk: RoHS Compliant Coke Vibration Screen
The RoHS Compliant Coke Vibration Screen is a heavyduty linear motion vibratory screener engineered specifically for metallurgical coke classification at 3mm to 25mm cut points. This equipment integrates RoHScompliant electrical components (leadfree solder, cadmiumfree contacts) and corrosionresistant alloys throughout the material contact surfaces.
Aliran Kerja Operasi:
1. Pengagihan Makanan: Coke material enters via a flared feed box with replaceable wear liners, distributing material across the full screen width
2. Primary Stratification: Linear vibration at 750–1000 RPM creates material bed fluidization, allowing fines to migrate to the screen deck
3. Klasifikasi saiz: Multideck configuration (2–4 decks) separates material into 3–4 fractions simultaneously
4. Pelepasan Bersaiz Besar: +25mm material exits via end discharge chute with ceramiclined impact zones
5. Fines Collection: 3mm material passes through to collection hopper with dust containment skirt
Skop Permohonan: Suitable for blast furnace coke, kok faundri, and petroleum coke processing at capacities from 50–400 tons per hour. Tidak disyorkan untuk bahan melebihi 8% moisture content without heated deck option.
Ciri Teras
HeavyDuty Screen Deck Construction | Asas Teknikal: AR400 abrasionresistant steel with 12mm thickness | Faedah Operasi: Withstands impact from 80mm coke lumps without deformation | Kesan ROI: Reduces deck replacement frequency from 18 bulan ke 36 bulan, saving $8,000–$12,000 per replacement cycle
Sistem Elektrik RoHSCompliant | Asas Teknikal: IEC 62321 certified components with leadfree solder and halogenfree wiring | Faedah Operasi: Full compliance with EU Directive 2011/65/EU for equipment exported to European markets | Kesan ROI: Eliminates $3,000–$5,000 per unit compliance testing costs and avoids potential $50,000+ noncompliance penalties
SelfCleaning AntiBlinding Mechanism | Asas Teknikal: Pneumatic deck rapping system with 50–80 psi air pulses at 30second intervals | Faedah Operasi: Mengekalkan 95%+ open screen area versus 60–70% on standard screens after 3 bulan | Kesan ROI: Increases effective throughput by 25–35% without additional power consumption
Reka Bentuk Dek Modular | Asas Teknikal: Quickrelease tensioning system with wedgelock fasteners | Faedah Operasi: Complete deck change in 4 hours versus 12–16 hours for bolted designs | Kesan ROI: Mengurangkan masa henti pertukaran oleh 66%, saving 8–12 hours of production time per change
Sistem Pembendung Debu | Asas Teknikal: Enclosed body with negative pressure plenum and cartridge filtration | Faedah Operasi: Meets OSHA PEL of 0.5 mg/m³ for respirable coke dust | Kesan ROI: Avoids $15,000–$25,000 annual ventilation upgrade costs and potential OSHA fines
Pemacu Frekuensi Boleh Ubah (VFD) Kawalan | Asas Teknikal: 3phase inverter drive with 0–100% speed range | Faedah Operasi: Adjusts vibration amplitude from 3mm to 8mm for different coke grades | Kesan ROI: Optimizes screening efficiency across varying feed conditions, reducing recirculation loads by 15–20%
CeramicLined Discharge Zones | Asas Teknikal: 92% alumina ceramic tiles bonded with epoxy | Faedah Operasi: Extends wear life in highimpact areas from 6 bulan ke 24+ bulan | Kesan ROI: Reduces annual maintenance costs by $4,000–$7,000 per discharge point
Kelebihan Kompetitif
| Metrik Prestasi | Piawaian Industri | RoHS Compliant Coke Vibration Screen | Kelebihan (% penambahbaikan) |
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| Screening efficiency at 6mm cut point | 85–88% | 93–96% | 8–9% higher recovery |
| Masa henti yang tidak dijadualkan (tahunan) | 12–18% | 4–7% | 55–67% pengurangan |
| Deck replacement interval | 18 bulan | 36 bulan | 100% hayat perkhidmatan yang lebih lama |
| Pembebasan habuk (mg/m³) | 1.5–2.0 | 0.3–0.5 | 75–80% lower emissions |
| Masa pertukaran (penuh dek) | 12–16 hours | 4 jam | 66–75% faster |
| Penggunaan kuasa (setiap tan) | 0.8–1.2 kWh | 0.5–0.7 kWh | 37–42% lower energy use |
| RoHS compliance certification | Partial/None | Full IEC 62321 | 100% patuh |
Spesifikasi Teknikal
| Parameter | Spesifikasi |
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| Julat Model | CVS48 (48" x 120") to CVS96 (96" x 240") |
| Kapasiti | 50–400 tons/hour (depending on cut point and feed size) |
| Julat Titik Potong | 3mm to 25mm (tunggal atau berbilang dek) |
| Jenis Getaran | Gerakan linear, 30°–45° angle |
| Kekerapan getaran | 750–1000 RPM (VFD adjustable) |
| Amplitud | 3–8mm (boleh laras) |
| Kuasa motor | 2 x 5.5 kW kepada 2 x 22 kw (dual drive) |
| Bekalan Kuasa | 380–480V, 3fasa, 50/60 Hz |
| Deck Material | Keluli AR400 (12mm), pilihan 304 keluli tahan karat |
| Pakai Pelapik | AR500 or 92% alumina ceramic |
| Electrical Components | RoHS compliant per IEC 62321 |
| Suhu Operasi | 20°C hingga +60°C |
| Berat | 4,500–18,000 kg (bergantung kepada model) |
| Dimensi (L x W x H) | 4.5m x 2.5m x 2.8m to 8.0m x 3.5m x 3.5m |
Senario Aplikasi
Blast Furnace Coke Processing at Steel Mill | Cabaran: Existing screen consistently produced 8–12% 6mm fines in +25mm oversize, causing furnace permeability issues and increased coke rate by 15 kg/ton hot metal | Penyelesaian: Installed CVS72 RoHS Compliant Coke Vibration Screen with 6mm and 25mm decks, VFD optimized at 850 Rpm | Keputusan: Oversize fines reduced to 2.3%, coke rate decreased by 12 kg/ton hot metal, simpanan tahunan sebanyak $480,000 in coke costs
Foundry Coke Classification for Export | Cabaran: Required RoHS compliance for EUbound shipments but existing equipment had leadbased solder in control panels and cadmium in proximity switches | Penyelesaian: Deployed CVS60 with full RoHScertified electrical system and ceramiclined discharge | Keputusan: Passed EU compliance audit on first inspection, export volume increased by 25%, avoided $65,000 in retrofitting costs
Petroleum Coke Processing at Refinery | Cabaran: High abrasion from calcined coke (Kekerasan Mohs 7.5) caused deck wear every 4 bulan, dengan 40% downtime for replacements | Penyelesaian: Implemented CVS48 with AR400 decks and pneumatic antiblinding system | Keputusan: Deck life extended to 14 bulan, downtime reduced from 18% ke 5%, annual maintenance savings of $92,000
Pertimbangan Komersial
Peringkat Harga Peralatan:
- Model Asas (CVS48, 2dek, 50 tph): $85,000–$110,000
- Model Standard (CVS72, 3dek, 200 tph): $145,000–$185,000
- Model Tugas Berat (CVS96, 4dek, 400 tph): $220,000–$280,000
- Heated deck system for highmoisture coke (+$12,000–$18,000)
- Stainless steel contact surfaces (+$22,000–$35,000)
- Remote monitoring with vibration sensors (+$8,500)
- Dust collection package with cartridge filters (+$15,000–$25,000)
- Kit alat ganti (skrin, galas, anjing laut): $4,500–$8,000
- Waranti Standard: 24 bahagian bulan, 12 buruh bulan
- Waranti Lanjutan: 48 bahagian bulan, 24 buruh bulan (+$12,000–$18,000)
- Preventive Maintenance Program: Pemeriksaan suku tahunan, annual rebuild (+$4,500/tahun)
- Pentauliahan & Latihan: 3day onsite installation support ($6,500)
- Jaring 30 syarat untuk pembeli yang layak
- Peralatan dipajakkan: 36–60 month terms at 4.5–7.5% APR
- Pembiayaan berasaskan prestasi: Pay per ton screened with minimum throughput guarantee
Ciri Pilihan:
Pakej Perkhidmatan:
Pilihan Pembiayaan:
Soalan Lazim
Q: Does the RoHS Compliant Coke Vibration Screen require special electrical infrastructure?
A: Standard 380–480V, 3phase power is sufficient. The VFD system operates on standard industrial power with 50/60 Hz compatibility. No additional transformers or phase converters are needed for most installations.
Q: How does RoHS compliance affect screen performance compared to noncompliant equipment?
A: Field data shows no performance degradation. The RoHScompliant electrical components (leadfree solder, halogenfree wiring) have equivalent or better thermal and mechanical properties. The primary difference is in material composition, not operational capability.
Q: What is the typical payback period for upgrading to this screen?
A: Berdasarkan data pelanggan daripada 12 pemasangan, average payback is 14–18 months. Ini menyumbang kepada masa henti yang dikurangkan (saving $40,000–$80,000 annually), improved screening efficiency (reducing recirculation by 15–20%), and elimination of compliancerelated costs.
Q: Can this screen handle coke with moisture content above 5%?
A: Standard configuration handles up to 5% moisture without issues. For 5–8% moisture, we recommend the heated deck option (thermostatically controlled to 60°C). Di atas 8% kelembapan, blinding becomes significant and alternative screening methods (mis., flipflow screens) may be more appropriate.
Q: What documentation is provided for RoHS compliance verification?
A: Each unit ships with a full compliance dossier including: IEC 62321 test reports for all electrical components, material declarations for alloys and coatings, supplier certificates of compliance, and a signed declaration of conformity. This documentation is accepted by EU customs authorities and thirdparty auditors.
Q: How does the antiblinding system affect maintenance requirements?
A: The pneumatic rapping system requires minimal maintenance—annual replacement of air filter elements ($120) and inspection of solenoid valves. The system operates automatically and does not require operator intervention. Compared to manual cleaning (which requires 2–4 hours per shift), this represents a 90% pengurangan dalam buruh.
Q: What is the lead time for custom configurations?
A: Standard models ship in 8–10 weeks. Konfigurasi tersuai (keluli tahan karat, dek yang dipanaskan, voltan khas) require 12–16 weeks. Tergesa-gesa pesanan (6–8 minggu) tersedia dengan a 15% premium. All units undergo full factory testing before shipment.