1. ABERTURA ACIONADA POR PAINPOINT

Sua operação de manuseio de coque é prejudicada pela qualidade inconsistente do produto?, geração excessiva de multas, e paradas de manutenção não planejadas? Para gerentes de fábrica que supervisionam a triagem de coque, common challenges directly impact profitability and throughput:
Contaminação do Produto & Rejections: Inefficient separation allows undersize fines to contaminate blast furnace feedstock or anodegrade product, leading to customer penalties and degraded metallurgical performance.
Premature Screen Deck Failure: The extreme abrasiveness of hot or cold coke accelerates wear on screen panels and support structures, causando frequentes, costly replacements and production stoppages.
Cegagem & Transferir: Sticky coke particles and moisture can blind screen apertures, enquanto vibração insuficiente leva ao transporte de material, drastically reducing effective screening capacity and classification accuracy.
Fadiga Estrutural & Transmissão de vibração: Poorly engineered vibratory motion transmits damaging harmonics to the base frame and surrounding infrastructure, risking longterm structural integrity.

Are you seeking a screening solution engineered not just to move material, but to precisely classify it while withstanding the punishing environment of coke handling? The right bespoke vibration screen is a capital investment in predictable grading and operational continuity.

2. VISÃO GERAL DO PRODUTO

A Bespoke Coke Vibration Screen is a heavyduty industrial screening machine specifically designed for the sizing, escalpelamento, or dedusting of metallurgical coke (cold or hot) e coque de petróleo. Engineered from the ground up for this application, it replaces generic screens that fail under abrasive loads.

Fluxo de Trabalho Operacional:
1. Alimentação controlada: Coke is introduced via a regulated feed chute onto the screen’s inlet section, distributing load across the full deck width.
2. Estratificação de alta intensidade: A precisely tuned vibratory mechanism (typically dual eccentric shaft or bruteforce design) imparts a linear or elliptical motion, aggressively stratifying material. Fines are forced downward to contact the deck.
3. Separação precisa: Stratified particles pass through accurately sized screen panel apertures (malha de arame, poliuretano, ou placa perfurada), separating into defined size fractions (por exemplo, +50milímetros, 50mm+25mm, 25milímetros).
4. Descarga Eficiente: Sized fractions discharge via dedicated chutes into separate collection conveyors or bins for downstream processing.

Escopo de aplicação: Triagem primária e secundária de coque metalúrgico (blast furnace foundry), coque de petróleo anodegrado, calcined coke. Suitable for sinter feed preparation and coke breeze recovery.
Limitações: Not designed for wet screening processes or as a replacement for crushers. Maximum feed temperature and particle size are defined by specific material specifications.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: Boltin panel subframes with tensioning rails | Benefício Operacional: Enables rapid changeover of worn screen media (<4 horas versus. 12+), minimizing downtime for maintenance crews. | Impacto do ROI: Reduces labor costs per changeout by ~60% and increases annual available production time.

Hot Coke Design Package | Base Técnica: Internal aircooled bearing housings & heatresistant seals | Benefício Operacional: Allows continuous operation with coke feed up to 250°C without bearing lubrication failure or seal degradation. | Impacto do ROI: Eliminates costly cooling periods before screening, increasing line throughput by maintaining process flow.

Anticegueira & Wear Systems | Base Técnica: Integrated ball tray decks or tensioned wire mesh with polyurethane cleaners | Benefício Operacional: Continuous microimpact dislodges sticky particles; wearresistant liners on decks/sideplates extend service life in highabrasion zones. | Impacto do ROI: Maintains nearoriginal capacity over longer campaigns; reduces consumable parts expenditure by 3040% anualmente.

Dynamically Tuned Vibratory Frame | Base Técnica: Análise de Elementos Finitos (FEA) distribuição de tensão otimizada & isolation spring system | Benefício Operacional: Contains vibratory forces within the screen body; minimizes harmful transmission to supporting structures (<90% isolation efficiency). | Impacto do ROI: Protects civil foundation investments and eliminates ancillary structural repairs.

DustEncapsulated Design | Base Técnica: Gasketed covers & dusttight discharge spouts with inspection ports | Benefício Operacional: Contains coke dust at transfer points, improving site air quality and reducing housekeeping labor. | Impacto do ROI: Lowers environmental compliance risk and reduces cleanuprelated operational delays.

Condition Monitoring Prep | Base Técnica: Preinstalled sensor pads (vibração, temperatura) on bearings with external junction box | Benefício Operacional: Facilitates easy integration into predictive maintenance programs for early fault detection. | Impacto do ROI: Evita falhas catastróficas nos rolamentos; enables planned shutdowns, avoiding 70+ hours of unplanned downtime per incident.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Generic Screen) | Solução personalizada de tela vibratória de coca-cola | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil do painel do convés| 36 months under abrasive load| 814 months with applicationspecific media| +130% para +150% |
| Eficiência de triagem| ~85% for 25mm separation| Consistentemente >92% for same separation| +8% ganho absoluto |
| Tempo de inatividade anual para manutenção de tela| 120180 horas (inspeções, mudanças)| 4060 horas (projeto modular)| 65% redução |
| Consumo de energia por tonelada filtrada| Linha de base (100%)| Massa otimizada & eficiência de condução| 15% redução |
| Rolamento MTBF (Tempo médio entre falhas)| ~12,000 hours in harsh service| >20,000 hours with cooling/sealing package| +67% melhoria |

Screening Efficiency defined as ratio of correctly sized undersize material recovered vs. total undersize in feed.

5. ESPECIFICAÇÕES TÉCNICAS

Classificação de capacidade: dependente do modelo; faixa padrão de 200 MTPH para 1,200 MTPH de coque a granel (80 lbs/ft³).
Unidade de acionamento: Dual eccentric shaft mechanism with greaselubricated spherical roller bearings. Alternative bruteforce designs available for highcapacity scalping.
Requisitos de energia: 15 kW para 55 motor kW (400V/50Hz ou conforme especificado), IP66 rated.
Configuração do convés: Solteiro, dobro, or tripledeck layouts based on cut points.
Opções de mídia de tela: Malha de arame de aço de alto carbono (hotgalvanized), painéis modulares de poliuretano, perforated manganese steel plates.
Quadro Estrutural: Heavyduty carbon steel plate construction with internal ribbing; shotblasted and coated with industrial epoxy paint system.
Dimensões Físicas (Typical DoubleDeck): Length ~7m x Width ~2.5m x Height ~3m (excluding supports).
Ambiente Operacional: Projetado para temperaturas ambientes de 20°C a +50°C; capable of processing material up to 250°C with hot package.

6. CENÁRIOS DE APLICAÇÃO

[Steel Mill Blast Furnace Feed] Desafio: A major integrated steelmaker experienced high variability in blast furnace coke size fraction (50mm+25mm), leading to irregular gas flow and increased fuel rate penalties estimated at €500k annually.Solução: Implementation of a tripledeck bespoke coke vibration screen with precise aperture control ahead of the furnace bins.Resultados: Achieved consistent sizing with <3% deviation in target fraction; reduced furnace fuel rate by 2%. Payback period was under 18 months via fuel savings alone.

[Planta de calcinação de coque de petróleo] Desafio: Anodegrade calciner needed to remove all 8mm fines from final product but faced rapid blinding of standard screens from residual volatiles.Solução: Installation of a bespoke linear motion screen featuring antiblinding ball trays and directheated deck panels.Resultados: Sustained screening efficiency above 94%; eliminated manual deck cleaning shifts; increased saleable product yield by an estimated 4%.

7. CONSIDERAÇÕES COMERCIAIS

Our Bespoke Coke Vibration Screens are offered in three primary tiers:
1. (Camada Básica): Standard Duty Screens, engineered core components with selectable media options—ideal for lowertonnage operations processing cooled coke.
2. (Nível recomendado): HeavyDuty Performance Screens, includes all core features listed above—the standard solution for most highvolume metallurgical applications requiring reliability.
3. (Nível Premium): SevereDuty Engineered Systems, includes full FEA analysis report customised feed/discharge hoods advanced instrumentation packages—specified for greenfield sites maximum operational data capture

Optional features include variable frequency drives process control integration custom skid bases extended warranty packages

Financing options include capital purchase lease agreements operating leases tailored support service packages provide scheduled inspections parts supply

8.Perguntas frequentes

Q1 Is your bespoke vibration screen compatible existing conveyor feed hoppers
Our engineering team will review your existing layout interface drawings We design custom inlet transition sections flanges ensure a proper fit minimal retrofit required during installation

Q2 Qual é o cronograma típico de comissionamento de instalação
From arrival site mechanical installation electrical connection dry run commissioning typically requires days supervised our engineer Delivery lead times vary based specification

Q3 How does this equipment impact overall plant noise levels
Properly installed isolated screens operate within dB(UM) range at meter distance meeting typical industrial environmental standards Acoustic enclosures are available option where required

Q4 What are payment terms delivery
Standard terms progress payment upon order confirmation payment prior shipment balance due upon completion Factory Acceptance Test Major projects may qualify structured milestone payments

Q5 Do you provide wear parts ongoing technical support
We maintain comprehensive inventory critical wear parts offer guaranteed hour dispatch key components Support packages include remote diagnostics annual health checks technician dispatches