1. ABERTURA ACIONADA POR PAINPOINT

Is your coke handling operation losing profitability to inefficient screening? Common challenges with conventional screens directly impact your bottom line. Você está experimentando:
Excessive Product Loss: Fines and valuable coke breeze passing through worn or inefficient screen decks, representando perda direta de receita com cada tonelada processada.
Alto tempo de inatividade para manutenção: Frequent failures of screen decks, rolamentos, or exciters due to the extreme abrasion and impact of coke, leading to unscheduled stoppages and production delays.
Cegagem & Poor Efficiency: Moisture or sticky fines blinding screen meshes, drastically reducing effective screening area and throughput, forcing recirculation and increasing energy costs.
Classificação inconsistente do produto: Unreliable particle size separation resulting in offspec product for blast furnace or foundry customers, risking contract penalties and reputational damage.
Preocupações com integridade estrutural: Constante, highimpact vibration leading to fatigue cracks in the screen body or support structure, creating major safety risks and costly capital repairs.

A questão central para os gerentes de fábrica é: como você pode conseguir resultados precisos, reliable coke classification while maximizing uptime and protecting your material yield?

2. VISÃO GERAL DO PRODUTO

The Export Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the dry classification of metallurgical coke and coke breeze. Designed for robustness in harsh environments, it separates crushed coke into precise size fractions critical for blast furnace efficiency and other industrial processes.

Fluxo de Trabalho Operacional:
1. Introdução ao feed: Sized coke from crushers is evenly distributed onto the feed box of the vibrating screen.
2. Estratificação & Separação: Alta intensidade, linear or circular vibration stratifies the material bed. Smaller particles descend to contact the screen cloth apertures, enquanto partículas maiores viajam pela superfície do convés.
3. Descarga de fração de tamanho: Correctly sized particles pass through the screen mesh (tamanho menor), while oversized particles discharge at the deck end (tamanho grande). Multideck configurations allow for simultaneous separation into several product grades.

Escopo de aplicação: Triagem primária e secundária de coque metalúrgico, coke breeze recovery, sizing for sinter plants, and prescreening for gasification processes.

Limitações: Não projetado para aplicações de peneiramento úmido ou para materiais com propriedades adesivas extremas sem tratamentos especializados de deck.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: As bolas, subframe mounted polyurethane or rubber clad steel panels | Benefício Operacional: Dramatically reduced replacement time; individual panels can be changed without full deck dismantling. | Impacto do ROI: Reduz o tempo de inatividade planejado para manutenção em até 60%, aumentando as horas de operação anuais.

HeavyDuty Exciter Assembly | Base Técnica: Internally mounted, greaselubricated vibrator unit with oversized bearings and labyrinth seals | Benefício Operacional: Isolated from direct material impact; delivers consistent amplitude under variable load conditions. | Impacto do ROI: Proven service intervals exceeding 8,000 horas em operação contínua, reducing spare part consumption.

HuckBolted Construction | Base Técnica: Highshear strength fastener system used throughout the main frame and side plates | Benefício Operacional: Eliminates weld fatigue failures; creates a rigid, maintenancefree body structure resistant to crack propagation. | Impacto do ROI: Prolonga a vida útil estrutural em anos, evitando custos prematuros de reposição de capital.

Tiered Dust Enclosure | Base Técnica: Multisegment rubber skirtboard system with quickrelease clamps at multiple transfer points | Benefício Operacional: Contains dust emission at feed, descarga, and side skirts; improves plant environmental compliance. | Impacto do ROI: Mitigates material loss as airborne fines and reduces housekeeping labor requirements.

Suspensão de mola ajustada | Base Técnica: Computermodeled coil spring or rubber buffer system matched to dynamic load parameters | Benefício Operacional: Isola até 85% de forças dinâmicas da estrutura de suporte; allows installation on elevated platforms. | Impacto do ROI: Eliminates costly structural reinforcement needs during installation and minimizes vibration transmission.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Telas Convencionais) | Export Coke Vibration Screen Solution | Vantagem (% melhoria) |
| : | : | : | : |
| Vida útil do painel do deck| 36 months with steel wire mesh | 1218 months with polyurethane clad panels | +150% melhoria média |
| Disponibilidade Anual| ~8590% (incluindo paradas planejadas)| >94% (dados de campo documentados) |>4 ganho de ponto percentual |
| Eficiência de triagem| 8590% on dry 6mm separation| Consistentemente >94% on same duty| +5% reduction in misplaced fines |
| Consumo de Energia por Tonelada| Linha de base (100%)| Unidade otimizada & o equilíbrio de massa reduz o empate em aproximadamente 15%| 15% lower operational cost |
| Instalação & Tempo de comissionamento| 57 days for full assembly on site| Preassembled modules reduce field work to 23 dias|<50% of standard time |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade / Avaliação: Dependente do modelo; variam de 500 MTPH para 2,500 MTPH of dry coke (bulk density ~0.50.6 t/m³).
Requisitos de energia: Acione motores de 15 kW para 45 kW por unidade vibratória (normalmente dualdrive), 400/690V e, IP66 protection standard.
Especificações de materiais:
Estruturas de convés & Placas laterais: Aço resistente à abrasão (AR400/450).
Plataformas de tela: Modular polyurethane panels with embedded steel reinforcement; optional rubberclad steel or tensioned wire cloth.
Quadro Principal & Membros Cruzados: Heavywalled structural steel with corrosioninhibiting primer.
Dimensões Físicas: Singledeck widths from 1.8m to 3.6m; comprimentos de 4,8m a 7,2m.
Faixa operacional ambiental: Temperatura ambiente de 20°C a +45°C; designed for outdoor installation with appropriate electrical components.

6. CENÁRIOS DE APLICAÇÃO

Integrated Steel Plant Blast Furnace Feed

Challenge A major steel producer faced consistent fines (5milímetros) contamination in their BFgrade coke (2575milímetros), affecting furnace permeability and increasing coke rate.
Solution Installation of a primary Export Coke Vibration Screen with two decks following secondary crushing.
Results Achieved a clean +25mm product with less than 3% undersize contamination while recovering 5mm breeze for sinter plant use—a quantifiable reduction of $12/ton in effective BF feed cost.

Produtor Comercial de Coca-Cola

Challenge Offspec product batches due to inconsistent screening after rain events caused moistureinduced blinding on traditional screens.
Solution Implementation of our screens equipped with specialized antiblinding polyurethane decks featuring slotted apertures and balltray cleaning systems.
Results Screening efficiency remained above 92% even with surface moisture up to 7%, eliminating penalty clauses related to product sizing in supply contracts within one quarter.

7 CONSIDERAÇÕES COMERCIAIS

Export Coke Vibration Screens are offered in three primary tiers:

1. Série de serviço padrão: For capacities up to ~800 MTPH. Includes core heavyduty construction features ideal for most merchant coke operations.
2. Série para serviços pesados: For capacities from ~800 MTPH to ~1,800 MTPH featuring enhanced exciter specifications and premiumtier bearing assemblies—the recommended choice for integrated steel plants.
3. Extra Heavy Duty Series: For ultrahighcapacity applications exceeding ~1，800 MTPH， incorporating duplex bearing exciters， design de moldura reforçada，and premium dust sealing packages．

Optional features include stainless steel fasteners，full stainless steel skirting，integrated spray systems for limited dust suppression，and condition monitoring sensor ports．

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including scheduled inspections，análise de vibração，and guaranteed spare parts availability．Financing options including equipment leasing are available through accredited partners．

Perguntas frequentes

Q What is the lead time for a typical Export Coke Vibration Screen?
A Lead times vary by model complexity．For standard configurations，expect delivery within X weeks upon order confirmation．Customized solutions may require additional engineering time．

Q Can this equipment integrate into our existing PLCcontrolled plant？
A Yes．All drives are compatible with standard industrial motor starters．The screen itself is supplied readyforsignal connection；it does not include complex control logic but can interface with your plant’s start/stop interlocks．

Q How does this design handle variations in feed rate？
A The exciter system generates a constant force independent of load．While efficiency is optimized at design capacity，field data shows performance degradation remains minimal (±2%) within a ±20% feed rate fluctuation．

Q What are the primary wear items？
A The primary consumables are the modular deck panels followed by wear liners on feed boxes．Spare parts kits based on recommended annual usage are available．

Q Do you provide installation supervision？
A Yes．Professional commissioning supervision is offered as an optional service package．This includes final alignment checks，initial startup assistance，and operator training．

Q Are your technical specifications guaranteed？
A All performance figures stated are based on standard test conditions using defined material characteristics．We provide written performance guarantees as part of our commercial proposal based on your specific application data sheet．

Q What financing structures do you offer？
A We work with thirdparty financial institutions that offer operating leases，capital leases/finance leases,and traditional purchase loans.Structures can be tailored over terms typically ranging from X years