1. ABERTURA ACIONADA POR PAINPOINT

Are you managing escalating costs and unpredictable downtime in your coke handling and classification process? Inefficient screening directly impacts your bottom line through lost production, excessive recrushing of onspec material, and premature wear on downstream equipment. Considere estes desafios operacionais comuns:
Cegagem & Transferir: Moisture and fine coke particles blind screen decks, reducing effective screening area and forcing oversized material into the product stream, comprometendo a qualidade.
Tempo de inatividade excessivo para manutenção: Conventional screens with highvibration components suffer frequent bearing failures, deck cloth damage, and structural fatigue, leading to unplanned shutdowns.
Baixa eficiência de triagem: Inconsistent material flow and poor stratification result in a high percentage of misplaced particles, wasting energy in reprocessing and failing to meet strict size specifications for blast furnace or foundry coke.
Altos custos operacionais: The combined effect of frequent part replacements, alto consumo de energia por tonelada processada, and laborintensive cleaning protocols erodes profit margins.

Is your current screening solution contributing to these issues? Um propósito projetado Peneira vibratória de coque is not merely a piece of equipment; it is a critical process control point designed to resolve these specific challenges.

2. VISÃO GERAL DO PRODUTO

The HeavyDuty Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the precise size separation of metallurgical coke (met coke) and petroleum coke (pet coke). It is built to handle abrasive materials while resisting the clogging effects of residual moisture and fines.

Fluxo de Trabalho Operacional:
1. Alimentação controlada: Sized coke from crushers is evenly distributed across the full width of the screen's feed box.
2. Estratificação & Separação: The dualvibrator generated linear motion rapidly stratifies material, forcing fines downward through the screen media while conveying oversize along the deck for discharge.
3. Descarga Eficiente: Correctly sized product passes through the deck apertures, while oversize is discharged at the end of the deck for return to crushers or separate stockpiling.

Escopo de aplicação: Primary sizing (escalpelamento) of runofoven coke, final product separation for blast furnace (2575milímetros) and foundry cokes, dedusting operations, and pet coke classification.

Limitações: Not designed for sticky materials without specialized screen media. Maximum feed size is limited by deck opening and structural design; typically handles lumps up to 300mm.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: Independently tensioned polyurethane or steel wire panels | Benefício Operacional: Panels can be replaced individually without full deck dismantling, reducing changeout time by up to 65%. | Impacto do ROI: Cuts maintenance labor costs and significantly reduces screen media downtime.

Dual CounterRotating Eccentric Shafts | Base Técnica: Synchronized masses generating a true linear motion | Benefício Operacional: Provides consistent material travel speed and optimal stratification with minimal power consumption per ton processed. | Impacto do ROI: Delivers higher screening efficiency (tipicamente 9295%) for reduced recrush loads and lower energy costs.

DustEncapsulated Vibrator Assemblies | Base Técnica: Labyrinth seals & pressurized grease purge systems | Benefício Operacional: Isolates critical bearings from abrasive coke dust ingress, the primary cause of bearing failure. | Impacto do ROI: Prolonga a vida útil do rolamento em mais 40%, preventing costly unplanned stoppages.

HuckBolted Construction | Base Técnica: Highshear strength aircraftstyle fasteners | Benefício Operacional: Creates a rigid frame that resists metal fatigue from constant vibration, eliminating weld failures. | Impacto do ROI: Garante a integridade estrutural ao longo de um 10+ vida útil do ano, protegendo seu investimento de capital.

Variable Slope Adjustment | Base Técnica: Hydraulic or mechanical deck angle modification (1525 graus) | Benefício Operacional: Operators can finetune material retention time based on moisture content or throughput requirements. | Impacto do ROI: Optimizes efficiency for varying feed conditions without sacrificing product consistency.

AntiBlinding Systems | Base Técnica: Optional ball tray decks or flexible urethane cleaning rings | Benefício Operacional: Continuous microimpact dislodges particles trapped in screen apertures. | Impacto do ROI: Maintains design capacity and product quality over extended runs, maximizing uptime.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Solução padrão da indústria | Nossa solução de peneira vibratória de coque | Vantagem (% Melhoria) |
| : | : | : | : |
| Eficiência de triagem (Accuracy) | 8588% typical for circular motion screens| Consistente 9295% achievable with linear motion & optimized decks| +8% reduction in misplaced material |
| Vida útil do rolamento (L10) in Coke Duty| ~8.000 10,000 horas| >14,000 hours with sealed vibrator design| +40% vida operacional mais longa |
| Deck Panel ChangeOut Time| Full deck bolt removal (68 horas)| Individual panel replacement (23 horas)| ~65% faster maintenance |
| Consumo de Energia por Tonelada Processada| Linha de base (100%)| Optimized mass & drive system reduces draw| Até 15% lower energy use |
| Structural Frame Integrity| Conventional welded design prone to crack initiation at stress points| Huckbolted monolithic frame resists fatigue failure| Os dados de campo mostram >90% reduction in framerelated weld repairs |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Available in widths from 1.2m to 3.6m; lengths from 4.8m to 10m. Capacidades de 200 TPH acima 2500 TPH depending on aperture size and material characteristics.
Requisitos de energia: Drive motors range from 2 x 7.5 kW para 2 x 55 kW (400/690V, 50/60hertz). Total installed power depends on machine size and load.
Especificações de materiais: Deck frames: Hardox or equivalent abrasionresistant steel. Side plates: Mild steel with replaceable abrasion liners. Screen Media Options: Tensioned polyurethane panels (mais comum), rubberclad perforated plate, or woven wire cloth.
Dimensões Físicas: Varia significativamente por modelo. Example Model CVC2448: Overall length ~9m; largura ~3m; height ~2.5m; peso aprox.. 12,500 kg.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Enclosed vibrator design allows reliable operation in highdust environments typical of coke plants.

6 CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant – Blast Furnace Feed Preparation

Challenge A major steel producer faced consistent blinding on their circular screens due to seasonal moisture variation in met coke.This caused excessive oversize carryover into the BF feed line,failing granulometry specs every winter season.Solution Installation of two widebody linear Coke Vibration Screens equipped with antiblinding ball trays.Solution Implementation Two widebody linear Coke Vibration Screens equipped with antiblinding ball trays were installed as final product screens.results Results Within one month,screening efficiency stabilized at94%.Oversize carryover was eliminated,and winterseason downtime for manual screen cleaning was reduced by80%.

Petroleum Coke Calcining Plant – Product Classification

Challenge A calciner needed precise separation of petcoke into three fractions(5milímetros,+515milímetros,+15milímetros)for different market grades.Their existing screens generated excessive fines(5milímetros)dust due aggressive vibration degrading fragile coke.results Results The plant switched to a tripledeck Coke Vibration Screen with precisely tuned stroke length frequency.solution Implementation A tripledeck Coke Vibration Screen with precisely tuned stroke length frequency was implemented.results Results Product yield improved notably.The+15mm lump fraction increased by7%,maximizing premium sales.Dust generation at the screen fell by an estimated30%,improving plant environment

Foundry Coke Producer – Scalping Oversize

Challenge An aging scalping screen before primary crushing suffered chronic structural weld failures every6months,causing72hour unplanned outages.solution Implementation A heavyduty Huckbolted frame Coke Vibration Screen replaced it handling300mm+feed material.results Results After24months continuous operation zero structural repairs have been required.Maintenance shifted entirely predictable component inspections

Considerações Comerciais

Pricing tiers are structured based on machine size construction level required duty

Standard Duty Series For general petcoke lower capacity metcoke applications.Pricing typically ranges$85000$220000 USD FOB

HeavyDuty Series For highcapacity abrasive metcoke primary scalping.Includes enhanced liners vibrators.Pricing typically ranges$180000$450000 USD FOB

Optional Features Customizable feed boxes discharge hoods multiple discharge points dust encapsulation covers various anti blinding systems rubber buffer isolators Condition monitoring sensors vibration temperature probes

Service Packages Include installation supervision commissioning support operator training Extended warranty plans Critical spare parts kits Annual inspection maintenance contracts

Financing Options We work with third party financial institutions offer equipment leasing structures operating leases capital leases facilitate cash flow management New system acquisition

FAQ Frequently Asked Questions

Q How do I determine correct size model my plant
A Selection requires analysis key parameters target throughput tons hour feed particle distribution percentage desired cut point mm moisture content Our application engineers provide detailed questionnaire guide specification process

Q Can this screen replace our existing circular motion unit footprint
A Linear motion screens often require longer footprint similar width Most retrofit projects involve minor modifications feed chute discharge hoppers Engineering drawings are provided feasibility review prior quotation

Q What typical lead time delivery
A For standard configurations lead time ranges12to20weeks order acknowledgment depending current production schedule Expedited options may be available additional cost

Q As peças sobressalentes estão prontamente disponíveis
A Yes We maintain global inventory critical wear parts vibrator assemblies deck panels tensioning components Standard parts are shipped within48hours emergency orders Longer lead items are clearly identified manuals

Q Do you offer performance guarantees
A Yes Our proposals include guaranteed minimum capacity tons hour specified material conditions guaranteed screening efficiency percentage based controlled test conditions These are formalized sales contract