1. ABERTURA ACIONADA POR PAINPOINT

Is your coke handling operation plagued by persistent bottlenecks and escalating costs? The screening phase is often a critical failure point, directly impacting downstream quality and overall plant throughput. Os desafios comuns incluem:

Cegagem & Transferir: A umidade e partículas finas de coque aderem às plataformas de peneiramento, blinding apertures and forcing material to carry over into the wrong product stream. Isso resulta em produto fora de especificação, aumento de cargas de rebritagem, e receitas perdidas.
Tempo de inatividade excessivo para manutenção: Traditional screens with complex drive mechanisms or fragile tensioning systems require frequent, lengthy shutdowns for deck changes, substituições de rolamentos, or structural repairs.
Alto consumo de energia & Tensão Estrutural: Inefficient vibration transmission and unbalanced forces lead to wasted energy and transfer damaging vibrations to the support structure, accelerating wear on the entire system.
Dimensionamento inconsistente: Inadequate screening efficiency causes undersized material to contaminate the sized coke product or valuable sized coke to be incorrectly diverted as fines, compromising product integrity and customer specifications.

Are you searching for a robust coke vibration screen engineered to maximize uptime, ensure precise separation, and reduce your total cost of ownership?

2. VISÃO GERAL DO PRODUTO

The HeavyDuty Coke Vibration Screen is a linear motion vibrating screen specifically engineered for the rigorous sizing and scalping of metallurgical and petroleum coke. Its design focuses on reliability in highabrasion, highcapacity environments typical in coke handling plants.

Fluxo de Trabalho Operacional:
1. Feed material from a conveyor is evenly distributed across the full width of the screen's inlet.
2. A synchronized dualshaft vibrator assembly generates a linear throwing motion, propelling coke particles along the screen deck.
3. Particles smaller than the deck aperture size stratify and pass through (tamanho menor), while larger particles travel across the deck to the discharge end (tamanho grande).
4. Separated streams are collected in distinct hoppers or onto separate conveyors for further processing or shipment.

Escopo de aplicação: Dimensionamento primário (por exemplo, separating +50mm from 50mm), scalpandscreen operations ahead of crushers, despoeiramento (removal of 3mm fines), and drainandrinse screen applications.

Limitações: Not designed for sticky materials without specialized deck treatments. Maximum feed size is limited by deck impact resistance; lump sizes exceeding 300mm typically require a grizzly scalper stage ahead of the screen.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: Independente, boltin panel construction with polyurethane or rubber media | Benefício Operacional: Panels can be replaced individually during scheduled maintenance without removing entire deck frames, reducing changeout time by up to 60%. | Impacto do ROI: Cuts labor costs for deck maintenance and significantly shortens downtime windows.

DualShaft Synchronized Vibrator | Base Técnica: Two counterrotating shafts with precisionmatched eccentric weights generate a pure linear force | Benefício Operacional: Provides consistent material travel velocity and stratification with minimal vertical motion, enhancing screening accuracy. The enclosed oilbath lubrication ensures reliable operation. | Impacto do ROI: Improved product yield accuracy reduces giveaway and reclaims lost revenue from missized material.

SubResonant Spring Support System | Base Técnica: Lownaturalfrequency coil springs isolate up to 95% de forças dinâmicas | Benefício Operacional: Dramatically reduces transmitted vibrations to the supporting structure, eliminating fatigue damage to feed and discharge chutes as well as the building steelwork. | Impacto do ROI: Lowers longterm structural maintenance costs and allows installation on elevated structures without costly reinforcement.

Tecnologia de deck antiofuscante | Base Técnica: Polyurethane or rubber screen panels with tapered apertures and optional balltray or airblast cleaning systems | Benefício Operacional: Prevents pegging and blinding by allowing particles to dislodge easily, maintaining consistent open screening area throughout operation. | Impacto do ROI: Sustains design capacity and screening efficiency over longer periods, preventing throughput drops that delay order fulfillment.

Robust Sideplate & Crossmember Construction | Base Técnica: Análise de Elementos Finitos (FEA) optimized steel fabrications with continuous welds at highstress points | Benefício Operacional: Withstands continuous impact from abrasive coke feed without cracking or deformation over a multiyear service life. | Impacto do ROI: Eliminates unscheduled downtime due to structural failure and defers major capital expenditure on body replacements.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Typical Linear Screen) | Nossa solução de peneira vibratória de coque | Vantagem (% Melhoria) |
| : | : | : | : |
| Eficiência de triagem (for 6mm separation) | 8590% sob condições ideais | Alcança consistentemente 9296% eficiência em testes de campo| +58% more product in spec |
| Tempo de substituição do painel do convés (Baralho completo) | 812 hours with crew of 34 | 35 hours with crew of 23 using modular system| ~60% faster changeover |
| Annual Bearing Service Life (Vibrador) | 1218 months in harsh service| Os testes da indústria demonstram 2430 month average life| +50% intervalo de serviço mais longo |
| Transmitted Dynamic Force to Structure| Alto; requires reinforced support| Isolated by subresonant spring system| Redução de até 95% |
| Power Consumption per Ton Handled| Linha de base (100%)| Optimized massandforce balance reduces draw by ~15%| ~15% lower energy cost |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Modelos disponíveis em 500 MTPH para 2,500 MTPH based on material density (~0.8 t/m³ for coke) and separation size.
Plataformas de tela: Single or double deck configurations. Larguras padrão de 1,5m a 3m; comprimentos de 4m a 8m.
Unidade de acionamento: Dualshaft vibrator with IP66rated motors. Faixa total de potência instalada: 15 quilowatts – 45 kW dependendo do tamanho do modelo.
Deck Media Options: Malha de arame tecido de alta resistência (padrão), painéis modulares de poliuretano (highwear areas), painéis de borracha (noise reduction).
Materiais de Construção: Quadro principal & sideplates: ASTM A36 steel with abrasionresistant liners at feed point. Fasteners are stainless steel or hotdip galvanized.
Ambiente Operacional: Projetado para temperaturas ambientes de 20°C a +50°C. Dusttight enclosures available for motor drives.

6. CENÁRIOS DE APLICAÇÃO

[Integrated Steel Mill – Sinter Plant Feed] Desafio: A major mill experienced rapid blinding on wire mesh decks when screening wet coke breeze (6milímetros) for sinter feed, causing hourly capacity drops of over 20%. Frequent manual cleaning posed safety risks.

[Solução] Implementation of a doubledeck Coke Vibration Screen fitted with antiblinding polyurethane panels on both decks and an integrated airblast cleaning system.

[Resultados] Eficiência de triagem estabilizada em 94%. Capacity returned consistently to design rate of 180 MTPH. As intervenções de limpeza manual foram eliminadas, aumentando a segurança do operador.

[Petroleum Coke Calcining Plant – Product Sizing] Desafio: The plant needed precise separation of calcined petroleum coke into three fractions (+25mm caroço, 25/+8mm nut, 8multas em mm). Their existing screens produced excessive amounts of "nearsize" material contaminating each fraction.

[Solução] A tripledeck Coke Vibration Screen was installed with precisely calibrated vibrator stroke & speed for multifraction separation.

[Resultados] A pureza do produto melhorou significativamente: contamination between fractions reduced by over 75%. This allowed the plant to meet tighter customer specifications for anodegrade coke command premium pricing.

7 CONSIDERAÇÕES COMERCIAIS

Our Coke Vibration Screens are offered in three primary tiers:

1. Série de serviço padrão: For capacities up to ~800 MTPH; ideal para plantas menores ou ciclos de trabalho menos severos.
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