1. ABERTURA ACIONADA POR PAINPOINT

Is your coke handling operation compromised by inefficient screening? Common challenges with standard vibratory screens directly impact your bottom line and plant reliability.

Excessive Downtime for Screen Deck Changes: Frequent blinding and wear of screen cloths halt your entire sorting line. Each changeover can cost hours of lost production and significant labor expense.
Classificação inconsistente do produto & Fines Contamination: Inadequate vibration control or poor deck design leads to offspec coke product. This results in rejected loads, customer penalties, and reduced product value.
Altos custos de manutenção & Component Fatigue: Harsh, abrasive coke particles rapidly degrade underengineered screen boxes, convés, e mecanismos vibratórios, leading to unplanned repairs and parts replacement.
Structural Integrity Concerns Under Load: Continuous hightonnage processing can induce stress cracks in welded frames or failures in isolation systems, creating safety risks and major capital repairs.

Are you seeking a screening solution that delivers consistent uptime, protects product quality, e reduz seu custo total de propriedade? The right industrialgrade Peneira vibratória de coque is engineered to address these exact operational challenges.

2. VISÃO GERAL DO PRODUTO

UM Peneira vibratória de coque is a heavyduty industrial screening machine designed for the highvolume sizing and scalping of metallurgical coke and similar abrasive materials in bulk handling plants. Its core function is to separate coke into precise size fractions (por exemplo, coque de alto forno, coque de nozes) enquanto remove finos e contaminantes.

Fluxo de Trabalho Operacional:
1. Alimentar & Distribuição: Raw or processed coke is fed onto the screen’s robust feed box, which evenly distributes material across the full width of the top deck.
2. Estratificação & Separação: Alta intensidade, vibração linear ou elíptica estratifica o leito de material. Smaller particles pass through apertures in the screen media (pano de arame, painéis de poliuretano), enquanto partículas maiores viajam pela superfície do convés.
3. Descarga & Transporte: Correctly sized fractions are discharged via separate chutes onto designated conveyors or into storage bins for downstream processing or shipment.

Escopo de aplicação: Dimensionamento primário de coque descarregado em forno, secondary screening for blast furnace feed, recirculating load separation in crushing circuits.
Limitações: Not designed for sticky or highly moist materials without pretreatment; maximum capacity is governed by particle size distribution and deck configuration.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: Boltin panel design with independent tensioning | Benefício Operacional: Os operadores podem substituir painéis desgastados individuais em menos de 30 minutes without dismantling adjacent sections. | Impacto do ROI: Reduz o tempo de inatividade do tecido da tela em até 65% versus traditional fulldeck replacements.

Conjunto de vibrador para serviço pesado | Base Técnica: Double eccentric shaft with oversized roller bearings housed in a rigid mass frame | Benefício Operacional: Generates consistent, highGforce vibration unaffected by load variance; lubricatedforlife bearings eliminate daily greasing points. | Impacto do ROI: Os dados de campo mostram um 40% aumento no tempo médio entre falhas (MTBF) compared to standard vibrator units.

Frame Stress Management | Base Técnica: Análise de Elementos Finitos (FEA) optimized side plates with reinforced cross members | Benefício Operacional: Minimizes harmonic distortion and fatigue stress points under cyclical loading, preventing frame cracking. | Impacto do ROI: Prolonga a vida útil estrutural em anos, evitando custos prematuros de reposição de capital.

Sistema de isolamento avançado | Base Técnica: Multistage rubbercoil composite springs or air isolators | Benefício Operacional: Absorve mais 95% of dynamic forces before they transfer to the support structure, protecting building integrity. | Impacto do ROI: Eliminates costly structural reinforcement needs and reduces ambient vibration affecting nearby equipment.

Pacote de revestimento resistente à abrasão | Base Técnica: Bolton wear plates made from AR400 steel at all critical impact points (caixa de alimentação, descarregar lábios) | Benefício Operacional: Protects the base frame from direct abrasion, ensuring longterm dimensional integrity of the screen body. | Impacto do ROI: Turns potential major frame repair into simple liner plate replacement, slashing longterm maintenance expenditure.

Projeto de contenção de poeira| Base Técnica: Integrated sealing flanges and skirt boards with durable rubber dust curtains| Benefício Operacional: Significantly reduces airborne particulate emission at feed and discharge points.| Impacto do ROI: Lowers environmental compliance risks and reduces material loss to atmosphere.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Nossa solução de peneira vibratória de coque | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade / Tempo de atividade | 8590% (incluindo. maintenance stops)| >94% disponibilidade desejada| +510% mais tempo de produção |
| Tempo de mudança de mídia de tela (Baralho completo) | 68 horas (soldado/aparafusado) | 34 horas (sistema modular)| 50% trabalho & tempo de inatividade |
| Vida útil do rolamento (Vibrador) | ~8,00010,000 hours| 14,000+ hours design life| +40% increased lifespan |
| Force Transmission to Structure| Até 25% dynamic force transfer|<5% dynamic force transfer|80% redução do estresse estrutural|
| Wear Life on Critical Liners(Aço suave)| 612 meses| 2436 meses (Aço AR400)| +200300% longevidade |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Sizes from 1.2m x 3m up to 2.4m x 6m; capacidades de 150 TPH até mais 1,200 TPH dependendo do tamanho da abertura e da gradação do material.
Dirigir & Requisitos de energia: Dual shaft mechanical vibrator driven by twin TEFC electric motors via Vbelts; faixa de potência de 15 kW até 55 kW per motor based on screen size.
Especificações de materiais: Estrutura principal construída em aço estrutural S355JR; side plates are minimum 10mm thick with additional wear liners; screen decks support tensioned wire cloth (highcarbon or stainless steel) or modular polyurethane panels.
Dimensões Físicas & Peso: Varia significativamente por modelo; por exemplo, a standard 1.8m x 4.5m unit has an approximate footprint of 5m L x 2.5m W x ~2m H; peso aprox.. ~812 tonnes.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C; dust protection rating standard IP65 for motors and electrical components.

6. CENÁRIOS DE APLICAÇÃO

Usina Siderúrgica Integrada – Preparação de Alimentação de Alto Forno

Challenge A major steel producer faced inconsistent blast furnace coke sizing (2575milímetros), with excessive fines (<10milímetros) causing permeability issues in the furnace burden column.
Solution Installation of a twodeck heavyduty Coke Vibration Screen with precisely calibrated wire cloth apertures for strict fraction control ahead of the furnace bins.
Resultados Obteve classificação consistente do produto com <3% fines contamination; furnace efficiency improved as measured by a documented reduction in coke rate by approximately 2%.

Coke Calcining Plant – Product Classification

Challenge Postcalcination screening was causing bottlenecks due to frequent blinding of fine screens handling hot abrasive coke (~150°C), requiring weekly shutdowns.
Solution Implementation of a specialized hotduty Coke Vibration Screen featuring heatresistant isolators and tensioned stainlesssteel mesh designed for hightemperature operation.
Results Increased runtime between scheduled maintenance from one week to over six weeks; plant throughput rose by an average of 18% due to eliminated unplanned stoppages.

7.CONSIDERAÇÕES COMERCIAIS

Our Coke Vibration Screens are offered under a tiered pricing structure based on size/capacity:

Nível de serviço padrão: Para menor tonelagem (<400 TPH) applications with standard features including basic liners coil spring isolation
Nível de serviço pesado (Recomendado para a maioria das aplicações metalúrgicas): Includes all core features listed above AR400 liners composite spring isolation premium bearing specs
Nível de engenharia personalizada: For extreme capacity unique spatial constraints or specialized materials includes full CFD/FEA analysis custom isolation solutions

Optional Features include acoustic hoods explosionproof motor ratings variable frequency drives for amplitude control automated lubrication systems

Service Packages range from basic commissioning support through comprehensive multiyear maintenance agreements covering planned inspections parts supply priority technical support

Financing options are available including straight purchase capital lease or operating lease structures tailored to align with your project budgeting cycles

8.Perguntas frequentes

Q What information is required ensure your Coke Vibration Screen compatible my existing layout?
A Provide detailed layout drawings current feed/discharge heights conveyor positions along required capacity(Toneladas/hora) desired final fractions(milímetros)

Q How does this equipment impact overall plant noise levels?
A Industry testing demonstrates proper isolation combined optional acoustic enclosures can reduce operating sound pressure levels below dB(UM)

Q Qual é o prazo de entrega típico da instalação?
A Lead times vary model complexity Standard Heavy Duty models typically available within weeks Custom engineered solutions require longer engineering fabrication timeline

P As peças sobressalentes estão prontamente disponíveis em todo o mundo??
A Yes maintain strategic inventory critical wear parts vibrator assemblies deck modules ensure expedited shipping minimize potential downtime events

Q Can existing older screens retrofitted any these features?
A In many cases yes offer retrofit kits modular deck systems upgraded isolation packages extend life improve performance legacy equipment site assessment required confirm feasibility

Q What warranty provided?
A All new Coke Vibration Screens carry comprehensive month warranty covering defects materials workmanship extended warranties available purchase

Q Do you offer performance testing before purchase?
A Yes can arrange pilotscale testing our facility provide representative sample material verify separation efficiency capacity estimates