1. ABERTURA ACIONADA POR PAINPOINT

Sua operação de manuseio de coque está enfrentando gargalos persistentes e custos crescentes?? A fase de triagem é muitas vezes um ponto crítico de falha, directly impacting downstream process stability and plant profitability. Os desafios comuns incluem:

Excessive Fines Carryover: Inefficient separation leads to valuable coke fines contaminating product streams or overloading crushers, degrading final product quality and increasing equipment wear.
Entupimento frequente da tela & Cegagem: Pegajoso, moist, or highfines feed material adheres to screen decks, drastically reducing effective screening area and throughput, forcing unscheduled downtime for manual cleaning.
Alta manutenção & Desgaste de Componentes: The abrasive nature of metallurgical coke accelerates the deterioration of screen panels, convés, e excitadores, resulting in high spare parts costs and laborintensive replacement cycles.
Dimensionamento inconsistente & Taxa de transferência: Inadequate vibration dynamics or screen surface design fail to handle variable feed rates and size distributions, causing offspec product and limiting overall plant capacity.
Excessive Structural Stress & Vibration Transmission: Poorly balanced or isolated equipment transmits damaging forces to support structures and buildings, leading to longterm integrity issues and safety concerns.

How can you achieve consistent product sizing with minimal downtime while controlling the total cost of ownership for your screening assets? The solution requires equipment engineered specifically for the harsh demands of coke classification.

2. VISÃO GERAL DO PRODUTO

The Certified Coke Vibration Screen is a heavyduty linear motion screening machine designed for the precise dry sizing and scalping of metallurgical coke in battery, classificação, and crushing circuits. Its robust construction addresses the unique abrasiveness, densidade, and operational demands of coke processing.

Fluxo de Trabalho Operacional:
1. Alimentação controlada: Coke feedstock is uniformly distributed across the full width of the screen inlet via an integrated feed box or chute.
2. Estratificação Eficiente & Separação: A highGforce linear motion stratifies material rapidly. Particles smaller than the screen panel apertures pass through as undersize, while oversize material conveys along the deck for discharge.
3. Descarga Positiva: Sized fractions are cleanly discharged from designated discharge spouts into separate chutes or conveyors for downstream processing.

Escopo de aplicação: Dimensionamento primário (escalpelamento) of runofoven coke, secondary sizing (classificação) of crushed coke for blast furnace burden, dedusting operations to remove fines (<10milímetros), and checkscreening in byproduct recovery circuits.

Limitações: Não projetado para peneiramento úmido ou aplicações de lama. Optimal performance requires controlled feed rates within specified capacity limits as per technical specifications.

3. RECURSOS PRINCIPAIS

Sistema de suporte de convés para serviços pesados | Base Técnica: Reinforced crossmembers with anticorrosion treatment | Benefício Operacional: Provides a rigid base for screen panels under extreme load, preventing sagging and ensuring consistent tension across all panel sections | Impacto do ROI: Extends panel life by up to 25%, reducing replacement part frequency and labor costs.

Advanced AntiBlinding System | Base Técnica: Strategically placed rubber balls or urethane strips beneath deck assemblies | Benefício Operacional: Creates secondary agitation at the screen mesh level to dislodge lodged particles that cause blinding | Impacto do ROI: Maintains up to 95% open screening area during operation, sustaining design throughput and eliminating frequent stoppages for cleaning.

DualMass Vibrator Assembly | Base Técnica: Two counterrotating eccentric shafts generating a linear force vector | Benefício Operacional: Delivers a consistent straightline motion ideal for material conveyance and stratification; starts smoothly under full load | Impacto do ROI: Reliable operation reduces stress on drive components (motores, cintos), lowering unplanned failures by an industrytested 30%.

Isolated Spring Suspension | Base Técnica: Highcycle steel coil springs or rubber buffer mounts at all support points | Benefício Operacional: Absorve mais 90% of dynamic forces generated by the vibrator assembly, impedindo a transmissão para a estrutura de suporte | Impacto do ROI: Eliminates costly structural reinforcement needs and minimizes vibrationinduced fatigue on surrounding infrastructure.

Modular Panel Design | Base Técnica: Interchangeable polyurethane or woven wire panels with varied aperture shapes/sizes | Benefício Operacional: Allows rapid configuration changes for different grade specifications; individual sections can be replaced without removing entire decks | Impacto do ROI: Reduces changeover downtime by approximately 40% compared to weldedpanel designs.

Enclosed Dust Management Design | Base Técnica: Integral dust sealing flanges at feed/discharge points with optional connection ports | Benefício Operacional: Contains airborne coke dust at transfer points, improving site air quality and operator safety | Impacto do ROI: Lowers housekeeping costs and facilitates compliance with workplace environmental regulations.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria (Típico) | Certified Coke Vibration Screen Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade de tela| Frequent stops for blinding clearance; ~85% runtime. Continuous operation with antiblinding; >92% runtime.| >8% melhoria |
| Panel Lifespan (Coca Abrasiva)| Woven wire panels last 34 months under heavy abrasion.| Specialized urethane/AR steel hybrid panels last 68 meses.| ~80100% improvement |
| Energy Efficiency per Ton Handled| Singlemass vibrators with standard motors; higher specific energy consumption.| Optimized dualmass drive with highefficiency IE3 motors.| Os dados de campo mostram 1520% melhoria |
| Transmitted Force to Structure| Significant dynamic force transfer requiring robust foundations.| >90% force isolation via tuned spring system.| Até 90% redução |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Disponível em larguras de 1,2m a 3,6m; comprimentos de 4,8m a 10m. Capacidades de 150 TPH acima 1500 TPH depending on model, aperture size, and material characteristics.
Requisitos de energia: Drive motor power ranges from 11 kW para 55 kW (400V/50Hz ou conforme especificado). All motors are IP66 rated for dust protection.
Especificações de materiais: Main frame constructed from S355JR structural steel with abrasionresistant liners at wear points. Deck support beams are hotdip galvanized. Screen panels available in hightensile woven wire (65Mn), polyurethane modular systems (95 Costa A), ou placa perfurada.
Dimensões Físicas (Example Model CCVS2448): Comprimento total: ~7.5m; Largura: ~2,8m; Altura (from spring base): ~2,1m; Peso: ~12,500 kg.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Bearings are rated for continuous operation up to +80°C surface temperature.

6. CENÁRIOS DE APLICAÇÃO

Blast Furnace Coke Preparation Plant

Challenge A major steel producer experienced excessive fines (<25milímetros) in their BFgrade coke due to inefficient scalping screens before crushing, leading to poor permeability in the furnace stack.
Solution Installation of twotier Certified Coke Vibration Screens configured with top deck scalping at 80mm apertures and bottom deck grading at 25mm apertures.
Results Fines content in final product reduced by over 60%. Crusher load decreased significantly due to effective scalpout of oversize material alone.

Byproduct Coke Sorting Station

Challenge Persistent blinding on existing screens handling moist runofoven coke caused hourly stoppages for manual rodding—approximately two hours lost production per shift—and inconsistent size distribution sent downstream.
Solution Retrofit installation of our solution featuring an advanced balltray antiblinding system on all three decks combined with polyurethane selfcleaning panels.
Results Screen blinding incidents reduced by over 90%. Plant achieved consistent fullshift operation without cleaning stops while improving size fraction accuracy within ±5mm specification bands consistently met

7 CONSIDERAÇÕES COMERCIAIS

Pricing tiers are structured based on machine size configuration complexity:
• Tier I Standard Duty Units For lowercapacity sorting lines start from competitive entrylevel pricing
• Tier II HeavyDuty Units For primary scalping hightonnage mainline applications represent our core offering
• Tier III Custom Engineered Systems For severeduty applications including fully enclosed designs special alloys fall under projectspecific quotation

Recursos opcionais incluem:
• Variable frequency drives For precise control over vibration amplitude frequency
• Hot material handling packages Including heat shields specialized seals
• Automated lubrication systems Centralized greasing points reduce manual maintenance
• Advanced monitoring packages With vibration sensors temperature probes predictive maintenance software integration

Pacotes de serviços disponíveis:
• Comprehensive commissioning supervision training
• Planned maintenance contracts covering annual inspections parts discounts
• Emergency breakdown support guaranteed response times

Financing Options Flexible capital expenditure solutions can be discussed including leasetoown arrangements operational leasing through our financial partners

8 Perguntas frequentes

Q What is lead time typical delivery schedule?
A Standard model delivery ranges between weeks upon order confirmation Custom configurations may require longer lead times detailed schedule provided upon quotation

Q Are screens compatible existing feed discharge chutework?
A Our engineering team provides detailed interface drawings dimensional data ensure proper integration into your current layout Minimal modification typically required due modular design

Q How does equipment impact overall plant noise levels?
A Enclosed design combined isolated spring suspension reduces operational sound pressure levels Industry testing demonstrates compliance most regional workplace noise regulations

P Qual cobertura de garantia é fornecida?
A We offer standard month warranty on entire machine excluding wear parts like screen panels Extended warranty options available purchase

Q Can you supply spare parts kits?
A Yes recommended initial spare parts kits tailored your expected usage patterns available order These typically include springs seals gaskets specific drive components

Q Do you provide installation services?
A Yes we offer full turnkey installation commissioning services performed certified technicians ensuring optimal setup performance from startup

Q What key factor maximizing screen panel life abrasive coke application?
A Correct tensioning during installation single most important factor Our commissioning service includes training your personnel proper tensioning techniques using calibrated tools