1. ABERTURA ACIONADA POR PAINPOINT

Is your coke screening operation plagued by persistent, costly inefficiencies? Para gerentes de fábrica e empreiteiros de engenharia, the challenges of screening bulk metallurgical coke directly impact throughput, qualidade do produto, and bottomline profitability. Obstáculos operacionais comuns incluem:

Cegagem & Transferir: Fine coke breeze and moisture cause screen mesh blinding, reduzindo a área de triagem eficaz. Simultaneamente, undersize material carries over with the product stream, contaminating blast furnace feed and degrading its performance.
Tempo de inatividade excessivo para manutenção: The abrasive nature of coke accelerates wear on screen decks, placas laterais, and exciters. Frequent component replacement leads to unplanned downtime and high spare parts inventories.
Separação ineficiente de multas: Inadequate separation of the 010mm fraction results in lost revenue from breeze sales and inefficient recycling within the coke plant.
Fadiga Estrutural & Failure: High Gforces from traditional vibrators transfer damaging stress to the screen body and support structure, leading to weld cracks and catastrophic frame failures.
Alto consumo de energia: Inefficient drive systems and oversized motors run continuously, contributing to significant, nonproductive power costs.

Are you seeking a solution that reduces downtime by 30% or more while ensuring consistent product sizing? The answer lies in selecting a coke vibration screen engineered specifically to overcome these materialspecific challenges.

2. VISÃO GERAL DO PRODUTO

The equipment in focus is a heavyduty Coke Classification Vibrating Screen, designed for highcapacity sizing of hot or cold metallurgical coke (25mm 80mm) from oven discharge and the subsequent separation of coke breeze (0mm 10mm).

Fluxo de Trabalho Operacional:
1. Alimentar & Distribuição: Bulk coke is uniformly fed onto the robust feed box, which distributes the material across the full width of the primary screen deck.
2. Dimensionamento Primário: A highstrength wire mesh or punch plate deck performs the primary separation, allowing undersize material (breeze and small fractions) to pass through.
3. Triagem Secundária & Remoção de Multas: A second deck further refines the separation, ensuring maximum recovery of marketable coke breeze.
4. Descarga: Correctly sized foundry or blast furnace coke discharges from the screen end, while separated fines are collected via a dedicated chute for processing or sale.

Escopo de aplicação & Limitações:
This equipment is designed for dry or slightly moist coke screening in fixed plant installations. It is not suitable as a replacement for rotary breakers or for handling highly sticky materials without pretreatment. Maximum lump size should not exceed 150% of the nominal top deck aperture.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: As bolas, pretensioned panel design with polyurethane side tensioning strips | Benefício Operacional: Individual deck sections can be replaced in under 2 hours without welding or specialized tools, minimizing downtime for maintenance. | Impacto do ROI: Reduces screen cloth changeout time by up to 60%, aumentando diretamente a disponibilidade da planta.

DualMass Drive Technology | Base Técnica: Two synchronized counterrotating masses generating a linear stroke | Benefício Operacional: Transfers dynamic forces into the screening motion rather than the support structure; allows for lower horsepower motors due to efficient energy transfer. | Impacto do ROI: Cuts structural maintenance costs by an estimated 40% and reduces operational energy consumption by 1525%.

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 main screen frame from wear, extending its service life beyond 10 years under typical conditions. | Impacto do ROI: Eliminates need for frequent frame repair or replacement, providing a predictable longterm asset cost.

Environmental Sealing System | Base Técnica: Multistage labyrinth seals combined with durable rubber dust curtains at transfer points | Benefício Operacional: Contains dust emissions at source, improving site environmental compliance and operator health conditions. | Impacto do ROI: Lowers costs associated with airborne particulate control and reduces housekeeping labor.

Tuned Spring Isolation | Base Técnica: Computermodeled coil spring or rubber shear mount system matched to screen weight and operating frequency | Benefício Operacional: Isola até 95% of dynamic vibration from the supporting structure, preventing damage to building foundations and adjacent equipment. | Impacto do ROI: Eliminates secondary structural costs and prevents costly vibrationinduced failures in plant infrastructure.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Solução de tela vibratória de coque | Vantagem (% melhoria) |
| : | : | : | : |
| Deck Panel Replacement Time| 68 horas (welded) | <2 horas (bolted modular) | ~70% mais rápido |
| Vida de fadiga estrutural| 35 years before major repair| 8+ years with protected frame| >100% aumentar |
| Eficiência de triagem (Breeze Removal)| ~85% efficiency| Consistentemente >92% eficiência| ~8% more product recovery |
| Operating Noise Level| 95105 dB(UM) e 1m| <85 dB(UM) e 1m| ~15 dB reduction |
| Annual Power Consumption| Linha de base (100%) for same duty| Reduced motor size + acionamento eficiente| 1525% redução |

5. ESPECIFICAÇÕES TÉCNICAS

Classificação de capacidade: dependente do modelo; faixa padrão de 300 MTPH para 1,200 MTPH of bulk coke (bulk density ~0.5 t/m³).
Requisitos de energia: Driven by dual lowvoltage AC motors (por exemplo, 2 x 11 kW para 2 x 30 kW), depending on model size and stroke configuration.
Especificações de materiais:
Quadro: Aço carbono resistente (S355JR), aliviado do estresse.
Convés: Options include highcarbon steel wire mesh (65Mn), HARDOX® punch plates, or polyurethane panels.
Wear Protection: AR400 steel liners standard at all impact zones.
Dimensões Físicas: Typical singledeck unit footprint ranges from (eu)6m x (C)2.5m x (H)1.8m to (eu)9m x (C)3.5m x (H)2eu.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C; capable of handling hot coke up to ~200°C with appropriate deck material selection.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant Coke Oven Battery Discharge

Desafio: A major steel producer faced severe blinding on their existing screens due to residual moisture in quenched coke. This caused frequent overloads on downstream crushers and inconsistent blast furnace feed sizing (+/15mm variance).
Solução: Implementation of two parallel heavyduty linear motion Coke Vibration Screens featuring nonblinding balltray decks on the fines removal section.
Resultados: Screening efficiency stabilized at ≥94%. Oversize contamination was eliminated (<1%), protecting crusher integrity. The consistent product sizing contributed to a documented ~3% improvement in blast furnace burden permeability.

Merchant Coke Producer – Breeze Recovery

Desafio: A merchant plant was losing significant revenue due to poor fines capture; an estimated 810% of saleable breeze was being incorrectly routed back into crusher feed circuits as "circulating load."
Solução: Retrofitting a dedicated Coke Vibration Screen with a finemesh secondary deck into their product classification circuit postcrushing.
Resultados: Breeze recovery increased from ~82% to over 95%, creating an additional revenue stream exceeding project payback within one year based on market prices for fuelgrade fines.

7.CONSIDERAÇÕES COMERCIAIS

Nossas peneiras vibratórias de coque são oferecidas em três níveis principais:
Série de serviço padrão: For capacities up to ~500 MTPH with robust base specifications; ideal for smaller plants or less severe duty cycles.
Série para serviços pesados (>500 MTPH): Our most common specification featuring all core technologies listed above; designed for continuous operation in integrated steel plants.
Soluções de engenharia personalizadas: For unique layouts requiring multiple discharge points specific grades like nut coke separation

Recursos opcionais incluem:
Enclosed designs with integrated dust extraction flanges
Stainless steel components for highly corrosive environments
Sensores avançados de monitoramento de condição
Inversores de frequência variável

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including guaranteed spare parts availability Financing options including leasing are available through our partners

Perguntas frequentes

What is your typical lead time?

For standard HeavyDuty Series models lead time is typically between weeks depending on current production schedules Custom engineered solutions require additional engineering time

Are your screens compatible with our existing chutes?

Our engineering team will review your existing layout drawings We provide detailed interface specifications including loads connection points ensuring seamless integration into your current transfer system

How do you guarantee performance?

Performance guarantees are based on agreedupon feed material characteristics We provide certified capacity curves based on laboratory testing data Guarantees typically cover throughput capacity under specified conditions

What does commissioning involve?

Our standard package includes supervision installation mechanical alignment initial startup process tuning We ensure correct operation before handover Documentation includes detailed manuals training materials

What are payment terms?

Standard commercial terms involve progress payments tied key milestones Typically % upon order % before shipment balance upon completion satisfactory commissioning Letters credit accepted Financing options available upon request