1. ABERTURA ACIONADA POR PAINPOINT

Sua operação de manuseio de coque é atormentada por gargalos persistentes e custos crescentes de manutenção?? Para gerentes de fábrica e empreiteiros de engenharia, a triagem ineficiente afeta diretamente os resultados financeiros. Os desafios comuns incluem:

Cegagem & Transferir: Fine, sticky coke particles blind screen decks, reducing effective screening area and forcing material carryover into the wrong product streams. This contaminates product grades and necessitates costly reprocessing.
Tempo de inatividade excessivo & Manutenção: Traditional screens with complex drive mechanisms and numerous moving parts require frequent lubrication, belt changes, and bearing replacements, leading to unplanned shutdowns.
Alto consumo de energia: Inefficient vibratory systems operate at constant high power, regardless of feed conditions, wasting significant energy over thousands of operational hours.
Fadiga Estrutural & Failure: The intense, reciprocating forces from conventional exciters transmit high stress to the screen body and support structure, leading to weld cracks, side plate failures, and shortened equipment lifespan.

Are you seeking a coke vibration screen solution engineered to minimize these operational burdens while maximizing throughput and product consistency?

2. VISÃO GERAL DO PRODUTO

Our engineered service provides heavyduty Coke Vibration Screens, specifically designed for the abrasive and demanding environment of coke handling in steel production, plantas anódicas, and calcining operations.

Fluxo de Trabalho Operacional:
1. Alimentar & Distribuição: Sized coke from crushers or ovens is fed onto the screen’s robust feed box for even distribution across the full width of the screening deck.
2. HighEfficiency Stratification: Um poderoso, linear vibratory motion stratifies the material bed, forcing fines downward through the screen media while conveying oversize toward the discharge end.
3. Separação precisa: Multiple deck configurations allow for precise separation into two or three distinct product streams (por exemplo, nut coke from breeze).
4. Descarga Controlada: Separated fractions are discharged via dedicated chutes for downstream processing or stockpiling.

Escopo de aplicação: Primary and secondary screening of metallurgical (conheci) coque, petroleum coke (Coca-Cola), and calcined coke in sizing ranges typically from 080mm.

Limitações: Not designed for extremely fine classification (<1milímetros) which requires specialized fine screening technology, or for materials at temperatures exceeding 250°C without specific design adaptations.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: Independently tensioned polyurethane or wire cloth panels on a rigid subframe | Benefício Operacional: Panels can be replaced individually without dismantling adjacent decks or extensive downtime. Damaged sections are isolated for quick changeout. | Impacto do ROI: Reduces deck replacement labor time by up to 60%, minimizando interrupções de produção.

Unidade Vibratória DualMass | Base Técnica: Two counterrotating eccentric masses generating a linear force along a defined stroke line | Benefício Operacional: Transmits dynamic forces internally within the vibrator assembly rather than to the screen body and support structure. Starts smoothly under full load. | Impacto do ROI: Cuts structural maintenance costs by up to 40% and extends overall screen frame life by years.

Huck Bolt® Frame Construction | Base Técnica: Highstrength aircraftstyle fasteners providing consistent clamp force across joints | Benefício Operacional: Eliminates weld fatigue failures at critical stress points on side plates and cross members under continuous vibratory loading. | Impacto do ROI: Dramatically reduces risk of catastrophic frame failure, ensuring multiyear structural integrity with minimal intervention.

Unidade de frequência variável (VFD) Compatibilidade | Base Técnica: Integration with VFD controls to adjust motor speed (RPM) | Benefício Operacional: Operators can finetune vibration amplitude and material travel speed in response to changes in feed rate or moisture content to optimize efficiency. | Impacto do ROI: Enables energy savings during lower throughput periods and optimizes performance without mechanical adjustments.

DustEncapsulated Bearing Assembly | Base Técnica: Labyrinth seals combined with positivepressure purge systems on vibrator shaft bearings | Benefício Operacional: Effectively excludes abrasive coke dust from critical bearing housings in a highparticulate environment. | Impacto do ROI: Extends bearing service life by 23x compared to standard seals, preventing a primary cause of drive failure.

AbrasionResistant Lining Packages | Base Técnica: Bolton wear liners made from AR400 steel or specialized ceramics at highimpact points (caixa de alimentação, descarregar lábios) | Benefício Operacional: Protects structural steel from direct abrasion, preserving base metal integrity. Liners are sacrificial components designed for easy replacement. | Impacto do ROI: Turns major plate repair projects into simple liner swaps, saving on both material costs and extended welding downtime.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Industry Standard Coke Screen Design | Nossa solução de peneira vibratória de coque | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade / Tempo de atividade| ~9294%, factoring in monthly maintenance stops for lubrication & adjustments.| >96%, achieved through sealedforlife vibrators & reduced lubrication points.| +34% aumento do tempo de produção |
| Deck Panel Change Time| 812 hours for full deck access & retensioning.| <4 hours via modular panel design & external tensioning system.| Até 60% mais rápido |
| Consumo de Energia por Tonelada| Fixed power draw regardless of load; estimado 0.15 kWh/ton.| VFDoptimized operation reduces draw under partial load; avg. 0.11 kWh/ton.| ~27% reduction possible |
| Tendo expectativa de vida| 1218 months in dusty conditions with standard seals.| 36+ months with multistage dust encapsulation systems.| +100% melhoria |
| Vida de fadiga estrutural| Major weld inspections/rework every 35 years due to stress cracking.| Huckbolted construction targets >10year frame life without major weld repair.| +100% melhoria |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade / Avaliação: Sizing capacities from 200 TPH acima 2,500 TPH depending on model aperture size.
Requisitos de energia: Drive motors ranging from 15 kW para 75 kW por unidade vibratória (normalmente dualdrive), compatible with 400/690VAC, 50/60Hz supply.
Especificações de materiais:
Quadro & Placas laterais: Highyield strength carbon steel (Q345B / A572 Grade 50 equivalent).
Deck Support Beams: Reinforced hollow section beams.
Screen Media Options: Tensioned polyurethane panels (para longevidade), woven wire cloth (for sharpness of cut), punch plate (for heavyduty scalping).
Dimensões Físicas: Larguras de 1,2m a 3,6m; lengths from 4.8m to over 10m for multideck configurations.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C; material temperature up to ~150°C standard (higher temp options available). Weather covers and dust enclosures are optional.

6. CENÁRIOS DE APLICAÇÃO

Preparação de alimentação de alto-forno para usina siderúrgica

Challenge A major integrated steel mill experienced frequent blinding on its primary nut coke screens due to residual moisture fines carryover was contaminating blast furnace burden impacting furnace efficiency
Solution Installation of two widebody Coke Vibration Screens featuring nonblinding polyurethane deck panels with a high open area percentage combined with an aggressive vibration stroke
Results Screening efficiency improved from ~85% to consistently above >94%. Product contamination was eliminated reducing blast furnace fuel rate by an estimated . Annual maintenance hours per screen were reduced by .

Petroleum Coke Calcining Plant

Challenge A calciner needed reliable classification of calcined petcoke into multiple product fractions but faced rapid wear on wire cloth decks requiring biweekly changes causing significant downtime
Solution Implementation of a tripledeck Coke Vibration Screen configured with an abrasionresistant ceramic feed liner package modular polyurethane decks on top/middle decks for durability longlife wire cloth on bottom deck
Results Deck life on top two decks extended sixfold bottom deck life doubled Total annual screeningrelated downtime was cut by Planned maintenance became predictable

ByProduct Coke Screening Station

Challenge An aging screening station suffered chronic structural cracks at welds leading emergency repairs every months The violent vibration also damaged surrounding infrastructure
Solution Replacement units featured our dualmass vibrator drive system Huck bolted frame construction significantly reducing dynamic forces transmitted into the support structure
Results No structural weld repairs have been required years postinstallation Vibration readings on the plant floor were reduced dB improving operator environment

CONSIDERAÇÕES COMERCIAIS

Equipment pricing tiers are structured based on size capacity robustness:

Tier Basic Duty Units designed lower capacity standalone replacement applications Tier HeavyDuty Units feature all core advantages listed above standard Tier SevereDuty Units include premium materials upgraded liners additional reinforcements extreme environments

Optional Features Include variable frequency drives automated lubrication systems multiple deck configurations special chutework custom skid bases comprehensive dust encapsulation

Service Packages range from basic commissioning supervision annual health inspections full longterm service agreements covering parts labor predictive maintenance planning

Financing Options available through partner institutions include equipment leasing capital loans payasyousave models tied efficiency guarantees facilitating budget management

Perguntas frequentes

What if my existing foundation cannot handle new vibration loads Our dualmass vibrator system transmits significantly lower dynamic forces foundations than traditional brute force designs Engineering review can confirm compatibility often eliminating need costly foundation upgrades

How does this design handle variations feed rate The linear motion is inherently stable under varying loads For optimal control pairing with an optional allows operators adjust stroke parameters realtime maintain peak efficiency despite feed fluctuations

Are spare parts readily available We maintain strategic inventory critical wear components like polyurethane panels tensioning hardware seal kits ensure availability minimize lead times unscheduled stoppages

What typical delivery lead time Standard designs have lead times weeks Customized configurations may require weeks Detailed project planning provided upon specification confirmation

Do you offer performance guarantees Yes we provide guaranteed capacity throughput based your specific material characteristics Guarantees cover mechanical performance first year operation terms outlined commercial agreement