1. ABERTURA ACIONADA POR PAINPOINT

Is your coke handling operation facing persistent bottlenecks and rising costs? A fase de triagem é muitas vezes um ponto crítico de falha, impactando diretamente o processamento downstream e a lucratividade geral da planta. Os desafios comuns incluem:

Cegagem & Transferir: Moisture and fine coke particles blind screen decks, while oversized material carries over into finished product silos. Isso resulta em produto fora de especificação, rejeições de clientes, and costly rehandling.
Tempo de inatividade excessivo para manutenção: Falhas frequentes em rolamentos, substituições de pano de tela, and structural weld cracks demand constant attention from your maintenance crew, stealing valuable production hours.
Alto consumo de energia & Transmissão de vibração: Inefficient vibratory mechanisms consume excess power and transmit destructive forces to the support structure, leading to accelerated wear on the entire screening station.
Separação de notas inconsistente: An inability to maintain precise cut points leads to product contamination, reducing the market value of your metallurgical or foundry coke.

Are you evaluating how a purposeengineered Peneira vibratória de coque can reduce your total cost of ownership, increase screening availability above 95%, and ensure consistent product quality?

2. VISÃO GERAL DO PRODUTO

UM Peneira vibratória de coque é uma alta capacidade, heavyduty screening machine designed for the scalping, dimensionamento, and dedusting of hot or cold metallurgical coke in battery, têmpera, and sorting plants. Its core function is to separate coke feedstock into precise size fractions (por exemplo, coque de alto forno, coque de nozes, brisa) ao remover multas.

Fluxo de Trabalho Operacional:
1. Bulk coke from the quench car or feed conveyor is discharged onto the screen's robust feed box.
2. Highmagnitude, linear or elliptical vibratory motion stratifies the material bed and propels it across the multideck screening surfaces.
3. Undersize material passes through sequentially smaller apertures on each deck.
4. Correctly sized fractions discharge at designated outlets for conveyor transfer to storage bins or loading stations.
5. Material de tamanho grande (por exemplo, +80milímetros) exits at the screen's discharge end for potential crushing or recirculation.

Escopo de aplicação: Dimensionamento primário e secundário de coque metalúrgico, coke breeze recovery, pré-seleção antes da britagem. Not suitable for sticky materials without specialized deck technology or as a replacement for a crusher.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: Independently tensioned polyurethane or steel wire panels | Benefício Operacional: Os painéis podem ser substituídos individualmente em menos de 30 minutes without dismantling adjacent decks | Impacto do ROI: Reduces screen cloth change downtime by up to 60%, aumentando a produtividade anual.

Dual Counterweight Vibrator Assembly | Base Técnica: Dois eixos excêntricos sincronizados gerando um movimento de lançamento linear | Benefício Operacional: Provides consistent material travel speed and stratification regardless of feed load fluctuations | Impacto do ROI: Melhora a eficiência da triagem ao 1520%, minimizing product contamination.

HuckBolted® Frame Construction | Base Técnica: Highstrength lock bolts applied with uniform tensile preload | Benefício Operacional: Eliminates frame weld fatigue failures common in bolted/riveted designs; withstands thermal expansion from hot coke | Impacto do ROI: Prolonga a vida útil estrutural em um valor estimado 35 anos, reducing major rebuild costs.

Labirinto & Grease Purge Sealing System | Base Técnica: Multistage seals with regulated grease pressure barrier | Benefício Operacional: Excludes fine abrasive coke dust from vibrator bearing housings under all conditions | Impacto do ROI: Increases bearing service intervals to over 12,000 horas, cutting lubrication costs by 30%.

Coil Spring & Rubber Buffer Isolation | Base Técnica: Progressiverate steel springs with rubber dampers on all support points | Benefício Operacional: Absorve até 95% de forças dinâmicas, impedindo a transmissão para a estrutura de suporte | Impacto do ROI: Eliminates costly structural reinforcement repairs and reduces surrounding equipment vibration damage.

Hot Coke Design Package | Base Técnica: Vedações resistentes ao calor, spaced deck frames for air flow, and hightemperature paint system | Benefício Operacional: Allows reliable operation with coke temperatures up to 200°C postquenching | Impacto do ROI: Enables direct screening after quenching without cooling conveyors, streamlining plant layout.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Nossa solução de peneira vibratória de coque | Vantagem (% melhoria) |
| : | : | : | : |
| Eficiência de triagem (Pureza de Grau) | ~85% 90% efficiency on moist fines| >95% efficiency maintained via adjustable stroke/frequency| +5% para +10% |
| Disponibilidade Anual (Tempo de atividade) | ~88% 92%, factoring cloth changes & reparos| >96%, supported by modular decks & sealed vibrators| +4% para +8% |
| Consumo de energia por tonelada filtrada| Linha de base (100%) referência| Aproximadamente 85% of baseline via optimized mass balance| Redução de ~15% |
| Rolamento MTBF (Tempo médio entre falhas)| ~8.000 horas de operação| >12,000 operating hours with advanced sealing| Increase of ~50% |
| Custo total de propriedade (5Período do ano)| Baseline cost inclusive of parts/labor/downtime| Estimado 2025% lower based on durability & ganhos de eficiência| Reduction of ~2025% |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Sizers from 1.2m x 3.0m to 2.4m x 6.0m; capacidades de 150 TPH acima 1,200 TPH of bulk coke.
Dirigir & Requisitos de energia: Dual shaft vibrator driven by twin TEFC electric motors via Vbelts. Motor power range: 2 x 7.5 kW para 2 x 45 kW (400V/50Hz ou conforme especificado).
Configuração do convés: Up to four decks standard; customizable slope angles (15° 25°).
Opções de mídia de tela: Painéis tensionados de poliuretano (para resistência à abrasão), painéis revestidos de borracha (for noise reduction), or heavyduty woven wire cloth.
Materiais de Construção: Main frame carbon steel ST37; Side plates wearresistant steel AR235/400; Deck support frames galvanized steel.
Dimensões Físicas: Varia significativamente por modelo; largest models require ~10m L x 4m W x 3m H footprint at operating angle.
Faixa operacional ambiental: Temperatura ambiente de 20°C a +50°C; capable of handling material temperatures up to +200°C with Hot Coke Package.

6. CENÁRIOS DE APLICAÇÃO

Usina Siderúrgica Integrada – Preparação de Alimentação de Alto Forno

Challenge A major steel producer faced inconsistent blast furnace feed quality due to excessive fines (<10milímetros) in their +25mm furnace coke fraction from existing screens.
Solution Installation of a primaryduty linear motion Coke Vibration Screen with two decks (40mm top deck aperture /25mm bottom deck aperture) postquenching tower.
Results Screening efficiency for the +25mm fraction increased from an estimated 96%. Fines carryover reduced by over90%. This contributed directly observed reductions in blast furnace specific fuel rate within expected parameters.

Merchant Coke Producer – Product Portfolio Expansion

Challenge A merchant cokery could not efficiently produce a highvalue "Nut Coke" fraction(1530milímetros) due limitations their aging rotary screens creating excessive degradation
Solution A dedicated sizing circuit featuring two parallel elliptical motion Coke Vibration Screens configured one scalp oversize one precisely split nutcoke fraction
Results Plant achieved clean separation nutcoke grade allowing entry premium market segment Overall plant yield increased approximately3through recovery previously lost midsize material

7.CONSIDERAÇÕES COMERCIAIS

Pricing for industrialgrade Coke Vibration Screens is determined by size capacity construction specifications Standard models typically fall into three tiers:

• Tier I Standard Duty(up500TPH): For lower capacity plants cooler temperatures Includes core features modular decks sealed vibrators
• Tier II High Capacity Duty(5001000TPH): Reinforced frames highperformance vibrators mandatory hotcoke package options
• Tier III Heavy Duty Custom(1000TPH+): Engineered specific applications may include special alloys automated tensioning systems

Recursos opcionais incluem:
• Variable frequency drive(VFD)for online stroke/speed adjustment • Dust encapsulation hoods • Automated lubrication systems • Advanced condition monitoring sensors

Pacotes de serviços disponíveis:
• Commissioning supervision • Planned maintenance agreements • Onsite inventory consignment kits critical spare parts

Opções de financiamento:
Capital expenditure can be structured through equipment leasing programs or project financing terms typically ranging3660months subject credit approval

8.Perguntas frequentes

Q What information needed ensure your screen compatible our existing layout?
A Provide basic dimensional footprint current machine along feed discharge heights connection points Flowrate desired fractions essential We will provide detailed GA drawing review

Q How does screen handle fluctuations feed rate common surge from quench cars?
A The dual counterweight design maintains consistent throwing force across wide range loads Material travel speed remains stable preventing flooding during surges ensuring separation quality

Q What typical installation timeline involve?
A For direct replacement foundation preparation followed mechanical erection electrical connection alignment Field commissioning usually requires35 working days experienced crew

P São oferecidas garantias de desempenho?
A Yes We guarantee mechanical performance uptime based agreed specifications offer throughput efficiency warranties supported field data similar installations

Q Can retrofit existing screen structure new vibrating assembly?
A In many cases yes Our engineering team assess feasibility retrofitting modernized vibrator units older structures potentially offering significant cost saving versus complete replacement

Q What lead time expected new unit?
A Lead times vary model complexity Standard configurations typically available within1216 weeks Custom engineered solutions may require1824 weeks planning

Q What key operational checks maximize screen lifespan?
A Daily visual inspections bolt tightness monthly checks spring condition quarterly vibration analysis readings Annual comprehensive inspection bearings media recommended