1. ABERTURA ACIONADA POR PAINPOINT

Is your coke processing line plagued by persistent bottlenecks and escalating operational costs? Para gerentes de fábrica e empreiteiros de engenharia, the screening phase is often a critical failure point. Os desafios comuns incluem:

Cegagem & Poor Separation: Fine, moist coke particles adhere to screen decks, causing rapid blinding. This forces either frequent manual cleaning or the acceptance of contaminated product streams, directly impacting product quality and saleable tonnage.
Tempo de inatividade excessivo para manutenção: Conventional screens require frequent shutdowns for screen cloth changes and bearing inspections. This unplanned downtime halts your entire processing line, custando milhares por hora em perda de produção.
Alto consumo de energia & Tensão Estrutural: Inefficient vibratory motion translates to wasted electrical power. Além disso, unbalanced forces can cause premature fatigue and cracking in the screen body and support structure, levando a falhas catastróficas.
Inconsistent Grade Control: Inability to maintain precise cut points results in offspec material—either oversized contaminants in the final product or valuable onspec coke reporting to waste.

Are you searching for a screening solution that delivers sustained throughput, minimizes unscheduled stops, and protects your profit margins? The right industrial vibration screen is not just a piece of equipment; it is a strategic investment in plant reliability.

2. VISÃO GERAL DO PRODUTO

The HeavyDuty Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the rigorous dry or slightly moist separation of metallurgical coke and petroleum coke. It is designed to handle abrasive materials at high temperatures with continuous 24/7 operação.

Fluxo de Trabalho Operacional:
1. Alimentar & Distribuição: Sized coke from crushers or ovens is evenly distributed across the full width of the screen's feed box.
2. Estratificação & Separação: Twin counterrotating vibratory motors generate a linear throwing motion, stratifying material. Smaller particles pass through precisely sized screen panel apertures.
3. Descarga: Correctly sized fractions are discharged via separate chutes—typically oversize (for recrushing), tamanho do produto, e multas.

Escopo de aplicação: Primary sizing (escalpelamento) and final grade separation of coke ranging from lump (por exemplo, +50milímetros) to nut coke (por exemplo, 1025milímetros). Suitable for sinter plants, blast furnace charging systems, and anodegrade coke preparation.

Limitações: Not designed for wet washing applications or for materials with extreme adhesive properties without specialized screen media.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: As bolas, pretensioned polyurethane or steel panel sections | Benefício Operacional: Reduces media change time by up to 60% compared to woven wire systems. Individual sections can be replaced without dismantling adjacent decks. | Impacto do ROI: Cuts labor costs for maintenance and increases annual available production time.

Dual CounterRotating Motor Drive | Base Técnica: Two synchronized vibratory motors generating a linear force vector | Benefício Operacional: Provides consistent material travel speed and stratification with minimal transmitted dynamic loads to the support structure. | Impacto do ROI: Lowers structural maintenance costs and ensures predictable screening efficiency for consistent product quality.

Fully Sealed Dust Guard System | Base Técnica: Multipoint rubber sealing between side plates and deck frames | Benefício Operacional: Contains dust emission at transfer points, improving site environmental compliance and operator health. | Impacto do ROI: Reduces risk of regulatory fines and housekeeping labor while protecting downstream equipment from abrasive dust ingress.

HighStress Frame Design | Base Técnica: Reinforced side plates with internal crossbracing and stressrelieved welds | Benefício Operacional: Withstands cyclic loading over extended service life, preventing frame cracking—a common failure point in demanding coke screening. | Impacto do ROI: Extends major asset lifespan beyond 10 anos sob dever severo, delaying capital replacement.

Centralized Greasing Labyrinth Bearings | Base Técnica: Bearing housings with labyrinth seals plumbed to a single grease nipple per bearing shaft | Benefício Operacional: Permite segurança, rapid lubrication during brief operational pauses without disassembly. | Impacto do ROI: Extends critical bearing service life by ensuring proper lubrication, preventing failures that cause weeklong downtime.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução de peneira vibratória de coque | Vantagem documentada |
| : | : | : | : |
| Screen Media Change Time (Baralho completo) | 1624 horas (woven wire) | 68 horas (modular panels) | Até 67% redução |
| Vida útil do rolamento (L10) under heavy load| ~12.000 horas | 18,000+ hours with recommended greasing regime| 50%+ melhoria |
| Integridade Estrutural (Time to first major frame weld repair) | Tipicamente 35 anos| Designed for 7+ years before major intervention| >40% intervalo de serviço mais longo|
| Screening Efficiency for 6mm fines removal at high moisture (92% efficiency with antiblinding panel options| ~8% increase in product purity|

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 2000 TPH depending on aperture size and material characteristics.
Drive & Poder: Dual vibratory motors ranging from 2 x 7.5 kW para 2 x 55 kW per unit (400V/50Hz or other standards). Total force output adjustable via motor weights.
Configuração do convés: Solteiro, dobro, or tripledeck layouts based on separation requirements.
Materiais de Construção: Quadro principal: S355JR structural steel; Side plates: Hardox® abrasionresistant steel; Screen panels: Polyurethane (Trellex®/Skega® type), punched steel plate, or rubber clad.
Dimensões Físicas & Mass: Varia significativamente por modelo; typical installed mass ranges from ~8 tonnes (small) para >35 toneladas (grande).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; material temperature handling up to +120°C with heatresistant components.

6. CENÁRIOS DE APLICAÇÃO

[Steel Mill Blast Furnace Feed] Desafio: A major integrated steel mill experienced frequent blinding on its final coke screens before skip charging, causing oversized material (+80milímetros) to enter the furnace burden at rates exceeding plant specifications (>3%). This disrupted furnace permeability.

[Solução]: Implementation of a tripledeck Coke Vibration Screen equipped with nonblinding rubber screen panels on the top deck for effective scalp removal of oversized pieces.

[Resultados]: Oversize contamination reduced consistently below <0.8%. Annualized reduction in fuel rate attributed partly to improved burden distribution was measured at approximately ~1%.

[Petroleum Coke Calcining Plant] Desafio: An anodegrade calciner needed precise separation of calcined petroleum coke into multiple fractions (12mm+6mm, 6mm+3mm). Their existing screens suffered rapid wear from abrasion required biweekly shutdowns for cloth changes.

[Solução]: Installation of two parallel doubledeck Coke Vibration Screens fitted with modular polyurethane screen panels rated for high abrasion resistance.

[Resultados]: Screen panel life extended from two weeks average upto eight weeks between changes resulting in an estimated gain of over two hundred production hours annually per line while maintaining sharp separations

7 CONSIDERAÇÕES COMERCIAIS

Our Coke Vibration Screens are offered as engineeredtoorder capital equipment

Níveis de preços:
Standard Duty Series For lower capacity replacement applications
HeavyDuty Series For new installations primary sizing
UltraDuty Series For highest tonnage plants abrasive conditions

Optional features include stainless steel dust covers hotmaterial adaptations special liners online condition monitoring sensors

Service packages range from basic commissioning comprehensive multiyear maintenance agreements including scheduled inspections parts supply priority technical support

Financing options available including leasetoown structures progressive payment plans aligned with project milestones facilitating easier budget allocation

8 Perguntas frequentes

Q What if my existing foundation cannot support new equipment
A Our engineering team can provide retrofit designs including custom support structures isolators adapt existing feed discharge chutes minimizing civil work costs

Q How does this screen integrate with my current PLC control system
A The vibratory screen operates as standalone machine but can be equipped standard Modbus TCP/IP Profibus interfaces allowing monitoring motor temperature vibration levels central control room

Q What typical lead time delivery
A Lead times vary based complexity configuration Standard HeavyDuty models typically available within weeks fully custom engineered solutions require detailed consultation provide accurate timeline

Q As peças sobressalentes estão prontamente disponíveis
A We maintain regional inventory critical wear parts modular screen panels motor sets bearing assemblies ensure maximum equipment availability reduce lead times emergency repairs

Q Can you provide performance guarantees
A Yes we offer guaranteed capacity separation efficiency specifications based certified test data your specific material sample processed our laboratory prior order confirmation