Assunto: Addressing Downtime and Contamination in Coke Screening Operations

1. ABERTURA ACIONADA POR PAINPOINT

Every ton of coke that bypasses your screening system represents lost revenue and potential downstream penalties. Os gerentes de fábrica enfrentam três desafios persistentes: blinding of screen media due to moisture and fines, fadiga estrutural from highimpact feed, e inconsistent cutpoint accuracy that leads to customer rejections. Industry data indicates that unscheduled downtime for screen deck replacement can cost a midsized coking facility upwards of $15,000 por hora em produção perdida. Adicionalmente, um 2% increase in fines contamination can trigger price deductions of $5–$8 per ton from steel mill buyers.

Are your current screens handling the abrasive nature of metallurgical coke without excessive wear? Can your equipment maintain a consistent 25mm or 50mm separation under 24/7 operação? The solution requires a machine built specifically for the highimpact, highwear environment of coke processing.

2. VISÃO GERAL DO PRODUTO

O Fabricante chinês de marca própria de peneira vibratória para coque offers a heavyduty, linearmotion vibrating screen engineered for the classification of metallurgical coke, coque de fundição, e coque de petróleo. This equipment operates on a dualshaft exciter system to generate a straightline stroke, propelling material across the deck for efficient stratification.

Fluxo de Trabalho Operacional:
1. Introdução ao feed: Coque (0–80 mm) enters the screen via a chute, with a feed box designed to absorb initial impact.
2. Estratificação: Linear vibration causes larger particles to rise to the top layer while fines migrate to the deck surface.
3. Separação: Material passes over polyurethane or perforated steel panels. Undersize falls through; viagens de tamanho grande até a extremidade de descarga.
4. Descarga: Two to three product streams (por exemplo, +50milímetros, 2550milímetros, 25milímetros) are directed to separate conveyors.

Escopo de aplicação: Ideal for dry screening of blast furnace coke, coque de nozes, e brisa de cocaína. Limitações: Not recommended for wet screening applications where moisture exceeds 12%, as this can cause rapid blinding.

3. RECURSOS PRINCIPAIS

HighStroke Exciter Assembly | Base Técnica: Dualshaft, counterrotating gearbox with eccentric weights | Benefício Operacional: Generates a 10–12mm stroke amplitude, preventing material stratification failure common in coke screening | Impacto do ROI: Reduces recirculation loads by 15%, lowering energy consumption per ton processed.

AbrasionResistant Deck Design | Base Técnica: 12mm thick polyurethane panels with 65 Dureza Shore A, or AR400 steel plate options | Benefício Operacional: Withstands the sharp, angular edges of coke particles, extending screen media life by 300% em comparação com a borracha padrão | Impacto do ROI: Decreases annual media replacement costs by approximately $8,000 por baralho.

Sistema de tensionamento QuickRelease | Base Técnica: Hydraulic or manual wedge tensioners on side plates | Benefício Operacional: Allows a twoman crew to replace a screen panel in under 30 minutos, contra 2 hours on bolted systems | Impacto do ROI: Recupera 1.5 hours of production time per changeout, valued at over $20,000 anualmente.

DustTight Sealing | Base Técnica: Compressionsealed side plates with labyrinth seals on bearings | Benefício Operacional: Prevents fugitive coke dust from entering bearing housings, a primary cause of premature failure | Impacto do ROI: Extends bearing service life from 6 meses para 18 meses, salvando $2,500 per bearing replacement.

Variable Angle Adjustment | Base Técnica: Adjustable support springs allowing deck angle from 15° to 25° | Benefício Operacional: Enables operators to finetune material retention time for varying coke moisture levels | Impacto do ROI: Improves screening efficiency by 5–8% during seasonal moisture changes.

Modular Deck Frame | Base Técnica: Aparafusados, segmented side plates | Benefício Operacional: Allows for partial deck replacement without removing the entire screen from the structure | Impacto do ROI: Reduces structural modification costs by 40% when upgrading to different media types.

HeavyDuty Cross Members | Base Técnica: 150mm x 150mm hollow structural sections with wear liners | Benefício Operacional: Resists bending and cracking from the impact of 50kg coke lumps falling from a 1.5meter height | Impacto do ROI: Eliminates structural weld repairs, which average $3,000 por incidente.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Tela genérica) | Solução de tela vibratória de coque | Vantagem (% melhoria) |
| : | : | : | : |
| Eficiência de triagem (25mm cut) | 8588% | 9497% | +10% |
| Vida da mídia na tela (Poliuretano) | 46 meses | 1218 meses | +200% |
| Bearing Replacement Interval | 6 meses | 1824 meses | +200% |
| Tempo de troca (Deck único) | 2 horas | 30 minutos | 75% |
| Nível de ruído em 1 Medidor | 95 dB(UM) | 85 dB(UM) | 10 dB(UM) |
| Structural Warranty Period | 1 ano | 3 anos | +200% |

5. ESPECIFICAÇÕES TÉCNICAS

| Parâmetro | Especificação (Model CVS2448) | Especificação (Model CVS3660) |
| : | : | : |
| Capacidade (Coque, 25mm cut) | 150–200 TPH | 300–400 TPH |
| Área da tela | 6 m² (24 pés quadrados) | 12 m² (36 pés quadrados) |
| Number of Decks | 2 (opcional 3) | 2 (opcional 3) |
| Frequência de vibração | 750–900 RPM | 750–900 RPM |
| Stroke Amplitude | 10–12 mm | 10–12 mm |
| Potência do motor | 2 x 11 kW (15 HP) | 2 x 22 kW (30 HP) |
| Material de Construção | S355J2+N Steel / AR400 Liners | S355J2+N Steel / AR400 Liners |
| Mídia de tela | Poliuretano (65UM) or Perforated Steel | Poliuretano (65UM) or Perforated Steel |
| Peso Operacional | 8,500 kg | 14,000 kg |
| Faixa de temperatura operacional | 20°C to +80°C | 20°C to +80°C |

6. CENÁRIOS DE APLICAÇÃO

Steel Mill Blast Furnace Coke Screening | Desafio: A steel producer in Hebei Province was experiencing 8% multas (10milímetros) carryover into their blast furnace feed, causing permeability issues and increasing coke rate by 5 kg per ton of hot metal. | Solução: Installation of a dualdeck Coke Vibration Screen with 25mm and 10mm polyurethane panels. | Resultados: Transição de multas reduzida para 2.5%. Blast furnace coke rate decreased by 4 kg/THM, saving the plant $1.2 million annually in coke costs.

Foundry Coke Processing Plant | Desafio: A foundry coke producer needed to produce a tight 50mm x 80mm specification for cupola furnaces, but their existing screen was blinding due to 8% teor de umidade. | Solução: Implementation of a singledeck screen with a 15° deck angle and 12mm stroke to maintain material flow. | Resultados: Screening efficiency improved from 82% para 96%. Customer rejection rate dropped from 5% para 0.5%, securing a longterm supply contract.

Petroleum Coke Classification | Desafio: A calcined petroleum coke facility required separation of +6mm and 6mm fractions for anode production, but standard screens suffered rapid wear from the abrasive, angular particles. | Solução: Customized screen with AR400 steel deck plates and a 10mm stroke. | Resultados: Screen media life increased from 3 meses para 14 meses. Maintenance downtime decreased by 70%.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços de equipamentos (FOB Shanghai Port):

• Modelo Padrão (CVS2448): $45,000 – $55,000 (2convés, polyurethane media, 15 HP motors)
• HeavyDuty Model (CVS3660): $78,000 – $95,000 (3convés, Revestimentos AR400, 30 HP motors, dust enclosure)
• Custom Engineered Model: $110,000+ (for specific feed chute integration, special alloy construction, or explosionproof motors)

Recursos opcionais:

• Sistema de Lubrificação Automatizado: $4,500 (reduces manual greasing frequency to quarterly intervals)
• Vibration Monitoring Kit: $6,200 (provides realtime bearing and stroke data for predictive maintenance)
• Spare Parts Package (2year supply): $12,000 (includes bearings, selos, e 4 sets of screen panels)

Pacotes de serviços:

• Básico (1ano): Remote technical support + 1 onsite commissioning visit.
• Prêmio (3ano): Includes Basic + quarterly inspection reports + 10% desconto em peças de reposição.
• Garantia de Desempenho: Contractual guarantee of 93% screening efficiency at specified capacity, with financial penalties if not met.

Opções de financiamento:

• 30% Down Payment + 70% L/C at Sight (Padrão)
• Alugar para propriedade: 36prazo do mês com 5% compra no final.
• Pagamento diferido: 50% abaixo, 50% after 90day performance acceptance.

8. Perguntas frequentes

P: Can this screen handle the high impact of direct feed from a crusher?
UM: Sim. The feed box is reinforced with 20mm thick AR400 wear plates, and the cross members are designed to withstand a drop height of up to 2 metros. We recommend a rubber impact panel at the feed point for additional protection.

P: What is the typical lead time for a custom private label order?
UM: Standard models ship in 45–60 days. Customengineered units with specific paint colors or branding require 75–90 days from design approval.

P: How does this screen perform with highmoisture coke (1012%)?
UM: The linear motion and adjustable deck angle help manage moisture. No entanto, for consistent performance above 10% umidade, we recommend specifying a heated deck option or a dewatering screen design.

P: What is the warranty on the vibrator assembly?
UM: The gearbox and exciter assembly carry a 24month warranty against manufacturing defects. Bearings are covered for 12 meses. Structural components have a 36month warranty against cracking.

P: Can I use my existing screen media with this machine?
UM: The frame is designed for modular polyurethane panels (305mm x 305mm) or perforated steel plates. Adapter kits are available for some common OEM patterns, but we recommend using our media for optimal tensioning and life.

P: What are the power requirements for installation?
UM: Standard models require 380V/50Hz/3phase. We can supply 460V/60Hz or 690V transformers as an option. The motor starter panel is included.

P: How do you handle aftersales support for international buyers?
UM: We provide a dedicated project manager for each order. Remote diagnostics are available via video call. For critical failures, we can dispatch a service engineer within 72 hours to most industrial regions.