1. ABERTURA ACIONADA POR PAINPOINT

Sua operação de manuseio de coque está enfrentando gargalos persistentes?, geração excessiva de multas, e custos de manutenção não planejados? Inefficient screening directly impacts your plant’s bottom line through lost product, aumento do consumo de energia para processos downstream, e tempo de inatividade dispendioso para substituições de decks de peneiras. Are you currently facing these challenges?
Cegagem & Transferir: Moisture and sticky fines blind screen meshes, reducing effective screening area and forcing material to carry over unscreened, contaminating your product fractions.
Desgaste Excessivo & Manutenção: The abrasive nature of hot coke rapidly degrades standard screen panels and deck components, leading to frequent shutdowns for replacements and high spare parts inventories.
Separação Ineficiente: Inconsistent vibration or inadequate screening area results in poor size distribution control, sending offspec material to crushers or battery bunkers, disrupting the entire production chain.
Fadiga Estrutural: The intense impact loads from coke discharge can cause premature failure of the screen body and support structures, risking major operational failure.

The right coke vibration screen is not just a separator; it’s a critical asset for throughput stability and product quality control.

2. VISÃO GERAL DO PRODUTO

The heavyduty coke vibration screen is a highcapacity, linear motion screening machine engineered for the primary sizing and scalping of metallurgical coke. It is designed to withstand extreme abrasion, impacto, and thermal stress in coke handling plants.

Fluxo de Trabalho Operacional:
1. Alimentar & Distribuição: Hot or cooled coke from a conveyor is discharged onto a robust feed box or plate, distributing the material evenly across the full width of the first screen deck.
2. Primary Stratification & Dimensionamento: The powerful dualvibrator motor drive generates a linear throwing motion. Esta ação estratifica o leito de material, forcing fines downward through the apertures of the upper deck(é) while conveying oversize toward the discharge end.
3. Fraction Separation: Vários níveis de deck (tipicamente 2 ou 3) with precisely sized screen media (rails, fio tecido, ou painéis de poliuretano) separate the coke into defined product streams (por exemplo, coque de alto forno, coque de nozes, brisa).
4. Descarga: Sized fractions are discharged via separate chutes for transport to storage bunkers or downstream processes.

Escopo de aplicação & Limitações:
Escopo: Ideal for primary screening of metallurgical coke after quenching or crushing; scalping of ovenrun coke; separation of coke breeze from larger fractions in byproduct recovery.
Limitações: Not designed as a dewatering screen for slurries. Maximum feed temperature is determined by specific component selection (por exemplo, heatresistant seals, motor isolators). Materiais extremamente pegajosos podem exigir pré-tratamento ou sistemas especializados de limpeza de convés.

3. RECURSOS PRINCIPAIS

Sistema de suporte de convés para serviços pesados | Base Técnica: Reinforced crossmembers with abrasionresistant wear liners | Benefício Operacional: Protects the main frame from direct material impact, drastically extending structural life | Impacto do ROI: Eliminates costly frame repairs; reduces lifetime structural maintenance costs by an estimated 6070%.

Acionamento vibratório duplo contra-rotativo | Base Técnica: Two synchronized motors generating a pure linear force | Benefício Operacional: Provides consistent material travel speed and stratification without elliptical motion; minimal transmission wear | Impacto do ROI: Ensures stable product sizing yearround; reduces drive maintenance compared to eccentric shaft designs.

Sistema de mídia de tela QuickChange | Base Técnica: Modular panel clamping with frontaccess tensioning | Benefício Operacional: Allows single operators to replace worn panels in under an hour without specialized tools | Impacto do ROI: Cuts downtime for media changes by up to 75%, aumentando diretamente a disponibilidade da planta.

Advanced Isolation Mounting | Base Técnica: Multilayered rubbercork or steel spring isolators tuned to machine frequency | Benefício Operacional: Absorve mais 95% de forças dinâmicas antes de atingirem a estrutura de suporte | Impacto do ROI: Protects building infrastructure from vibration damage; eliminates secondary support costs.

Hot Material Construction Package | Base Técnica: Heatdeflecting covers on vibrators, hightemp labyrinth seals on bearings, heatresistant paint systems | Benefício Operacional: Ensures reliable operation when handling hot coke directly from quench towers | Impacto do ROI: Increases component lifespan in highheat applications by over 40%, protegendo seu investimento de capital.

Sistema de Lubrificação Centralizada (Opcional) | Base Técnica: Automated greasing lines feeding all critical bearing points on vibrator shafts | Benefício Operacional: Guarantees proper lubrication intervals in hardtoaccess areas under all operating conditions | Impacto do ROI: Evita falhas catastróficas nos rolamentos; extends bearing service life by up to 50%.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria | Nossa solução de peneira vibratória de coque | Vantagem (% Melhoria) |
| : | : | : | : |
| Panel Life (Upper Deck) | Standard Hardox 400 Rails ~4 Months| Proprietary Alloy Cast Rails with Hardfacing ~9 Months| +125% vida útil |
| Eficiência de triagem (para fração alvo)| ~8892% efficiency under load| Consistente >95% efficiency under load| +35 pontos percentuais |
| Tempo de inatividade anual para manutenção de tela| ~120150 horas/ano| 50% redução |
| Força Dinâmica Transmitida à Estrutura| High transmission requiring reinforced foundations|95% redução na força transmitida |
| Consumo de energia por tonelada filtrada| Linha de base = 100%| Optimized mass/force balance reduces consumption by ~15%| 15% menor custo de energia |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade da gama de modelos: De 500 TPH acima 2,500 Capacidade de transferência de TPH.
Plataformas de tela: Tipicamente 2 ou 3 convés; configurações personalizadas disponíveis.
Impulsione a potência: Motores vibratórios duplos que variam de 2 x 15 kW para 2 x 55 kW dependendo do tamanho do modelo e da função.
Vibration Frequency/Frequency: Fixed frequency typically between 9001000 RPM; stroke adjustable via counterweight configuration.
Materiais de Construção: Main frame heavyduty steel plate (S355JR+). Wear surfaces AR400 steel liners. Screen media options include alloy cast rails (padrão), tensioned woven wire mesh, or modular polyurethane panels.
Dimensões Físicas (Modelo de exemplo): Widths from 1.8m to 3.6m; lengths from 6m to over 11m overall.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C. Specific hotduty packages allow handling feed material up to ~200°C intermittently.

6. CENÁRIOS DE APLICAÇÃO

Usina Siderúrgica Integrada – Preparação de Alimentação de Alto Forno

Desafio: A major steel producer experienced rapid blinding of woven wire screens during humid conditions at their BF coke bunker station. This caused significant nut coke fraction carryover into blast furnace feed bins (~12%), disrupting burden permeability and increasing fuel rate.
Solução: Implementation of two largecapacity linear motion screens fitted with nonblinding rod deck media on the upper decks for scalping oversize and openprofile polyurethane panels on lower decks for precise nut/breeze separation.
Resultados: Screening efficiency stabilized above 96%. Carryover was reduced to <3%. The plant reported an annual reduction in fuel rate attributed partly to improved burden control alongside a 65% drop in monthly screenrelated downtime.

Coke Plant – ByProduct Recovery Circuit

Desafio: A standalone coking plant needed to maximize recovery of saleable “nut” coke from its crushing circuit but struggled with excessive generation of undersize “breeze” due to aggressive screening action degrading fragile pieces.
Solução:: Installation of a threedeck unit featuring adjustable stroke length via external counterweights on its vibrator motors was selected. This allowed operators finetune intensity based on feed characteristics..
Resultados: By optimizing stroke,,the plant increased yield within target nut size range (+8%) while reducing undersize generation (15%). The gentler handling also extended lowerdeck panel life by approximately 30%.

7 CONSIDERAÇÕES COMERCIAIS

Níveis de preços
• Standard Duty Units: For cooledcoke applications with moderate tonnage (<1000 TPH). Offers core reliability features at an entry point..
• HeavyDuty / Hot Material Units: Includes full abrasion/heat packages,,upgraded drives,,and isolation systems.. Priced approximately 2540% above standard duty..
• Custom HighCapacity Units: Engineered solutions exceeding 2000 TPH capacity often require projectspecific pricing based detailed engineering study..

Recursos opcionais
• Enclosed Dust Housing: With flanged connections..
• Various Chute Configurations: Including wearlined,,insulated,,or heated designs..
• Vibration Monitoring System: With sensors providing realtime data predictive maintenance schedules..
• Variable Frequency Drive Control: For precise adjustment material travel speed..

Pacotes de serviços
• Commissioning Supervision
• Annual Inspection Contracts
• Critical Spares Kits
• Onsite Training Operators Maintenance Staff

Opções de financiamento
Financiamento de equipamentos de capital,,operating leases available through partners terms ranging 24 84 months subject credit approval..

8 Perguntas frequentes

Q1 How do I determine correct size model my application?
A Selection requires analysis total feed tonnage particle size distribution desired products moisture content We provide detailed questionnaire our engineers use recommend specific model configuration

Q2 Can existing foundation be used replacement unit?
A Possibly Our team requires drawings existing structure load data new unit We design adapter frames facilitate retrofits minimizing civil work costs

Q3 What typical lead time delivery?
A For standard models within catalog lead time ranges 16 weeks exworks Custom highcapacity units require longer engineering manufacturing schedule

Q4 As peças sobressalentes estão prontamente disponíveis?
A Yes We maintain global inventory critical wearing parts including vibrator assemblies deck panels isolation elements Standard parts shipped within hours emergency orders

Q5 Vocês oferecem garantias de desempenho?
A Yes We guarantee mechanical performance throughput capacity screening efficiency based agreedupon test protocols provided feed specifications met

Q6 How handle installation commissioning?
A We provide comprehensive installation manuals foundation drawings supervision available optional extra ensure correct setup initial operation

Q7 What expected operational lifespan main structure?
A With proper maintenance isolation our screens designed minimum years service before major structural overhaul required Field data supports this timeline numerous installations