1. ABERTURA ACIONADA POR PAINPOINT

Is your coke screening operation plagued by persistent inefficiencies that erode profitability? Para gerentes de fábrica e empreiteiros de engenharia, the challenges of screening highquality metallurgical or foundry coke are multifaceted. Are you experiencing excessive fines generation due to aggressive screening action, directly reducing your yield of premium product? Does frequent screen cloth blinding from sticky coke breeze lead to constant downtime for manual cleaning, interrompendo toda a sua linha de processamento? Are you battling with premature wear on screen decks and components from highly abrasive materials, resulting in unpredictable maintenance costs and parts replacement cycles? Além disso, does the inherent dust generation during screening create environmental control issues and product loss? These operational hurdles translate into quantifiable costs: rendimento reduzido, higher labor for maintenance, increased spare parts inventory, and suboptimal product grading that affects sales revenue. A questão central é: como você pode conseguir resultados precisos, eficiente, and reliable coke classification while maximizing the yield of your highvalue product fraction?

2. VISÃO GERAL DO PRODUTO

This content details a specialized HighQuality Coke Vibration Screen, an industrialgrade screening machine engineered for the dry separation of metallurgical and foundry coke into precise size fractions. Its design prioritizes gentle yet effective material handling to preserve coke integrity.

O fluxo de trabalho operacional é direto:
1. Introdução ao feed: Sized coke from crushers or feed stockpiles is evenly distributed onto the screen's inlet.
2. Separação Estratificada: A controlled vibratory motion stratifies the material bed, allowing undersize particles (coke breeze) to pass through the specified screen cloth apertures.
3. Descarga do Produto: Correctly sized oversize material (lump coke) discharges at the head end, while undersize material collects beneath the deck for separate conveyance.
4. Operação Contínua: The system operates continuously under heavy load, with parameters adjustable to match specific feed characteristics.

Application scope includes primary sizing of oven discharge coke, secondary screening for blast furnace fractions (por exemplo, 2580milímetros), and recovery of breeze from runofoven material. This equipment is not designed for wet screening or for processing extremely hot materials directly from ovens without appropriate cooling.

3. RECURSOS PRINCIPAIS

LowStress Vibration System | Base Técnica: Balanced elliptical or linear motion drive | Benefício Operacional: Conveys material with sufficient energy for separation while minimizing violent tumbling | Impacto do ROI: Reduces fines generation by up to 15%, preserving premium lump coke yield.

Tecnologia de deck antiofuscante | Base Técnica: Multiplestrand tensioned wire mesh or polyurethane panels with nonstick coatings | Benefício Operacional: Prevents adhesion of moist or sticky breeze particles | Impacto do ROI: Cuts downtime for screen cleaning by over 50% and maintains consistent throughput.

Construção resistente à abrasão | Base Técnica: Hardox or equivalent wear liners at feed points, reinforced deck frames | Benefício Operacional: Protects critical areas from rapid degradation caused by abrasive coke | Impacto do ROI: Prolonga a vida útil das peças de desgaste ao 3040%, reduzindo o custo por tonelada.

DustContained Design | Base Técnica: Enclosed decks with sealed dust hoods and integrated connection points for extraction systems | Benefício Operacional: Minimizes airborne particulate release at transfer points | Impacto do ROI: Reduces product loss as dust and simplifies compliance with site environmental standards.

Modular Screen Decks | Base Técnica: Independently tensioned deck sections with quickchange clamping systems | Benefício Operacional: Allows for rapid panel replacement or aperture changes during planned maintenance | Impacto do ROI: Reduces screen cloth changeover time by up to 60%, aumentando a disponibilidade da planta.

Precision Motion Control | Base Técnica: Adjustable eccentric weights or variablefrequency drive (VFD) on vibrator motors | Benefício Operacional: Operators can finetune amplitude and frequency to match specific feed rates and moisture content | Impacto do ROI: Optimizes efficiency across varying feedstock conditions without sacrificing grade.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | HighQuality Coke Vibration Screen Solution | Vantagem (% melhoria) |
|||||
| Screen Cloth Lifespan | 46 weeks under heavy abrasion | 812 weeks with optimized vibration & materiais | +80% |
| Eficiência de triagem | 8590% accuracy on size separation | Consistente 9396% precisão | +7% |
| Geração de Multas | Linha de base | Reduced by controlled material trajectory |15% |
| Downtime for Maintenance | 812 hours monthly for cleaning/changeouts

46 horas mensais |50% |
| Energy Consumption per ton | Standard motor rating

Optimized drive design reduces kWh/ton |10% |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade & Avaliação: dependente do modelo; faixa padrão de 200 para 1,500 toneladas métricas por hora (MTPH). Designed for material bulk density of ~0.5–0.8 t/m³ (coque).
Requisitos de energia: Driven by dual outofbalance vibrator motors; potência total instalada de 7.5 kW para 45 kW depending on screen size and duty.
Especificações de materiais:
Estrutura do convés & Sideplates: Aço carbono (S355JR) or abrasionresistant steel (Hardox 400).
Opções de mídia de tela: Tensioned highcarbon steel wire mesh (65Mn), stainless steel mesh (304/316), or modular polyurethane panels.
Molas & Rolamentos: Highcycle rubber buffer springs or coil springs; rolamentos autocompensadores de rolos para serviços pesados.
Dimensões Físicas: Solteiro, dobro, ou configurações de três andares; typical deck widths from 1.2m to 3.0m; lengths from 3.0m to 8.0m.
Faixa operacional ambiental: Ambient temperature operation (20°C a +40°C). Feed material temperature should be stabilized below 80°C to protect screen media and seals.

6. CENÁRIOS DE APLICAÇÃO

[Metallurgical Coke Plant Blast Furnace Feed] Desafio: A major steel producer needed consistent supply of +25mm lump coke but faced high fines content (10milímetros) exceeding furnace specifications after primary crushing and screening.

[Solution HighQuality Coke Vibration Screen Implementation]: A tripledeck unit replaced an older screener, configured with precisely tuned amplitude to minimize drop height between decks.

[Resultados Resultados Quantificáveis]: Fines generation in the target +25mm fraction was reduced by 18%. Annual yield of saleable blast furnace coke increased by approximately $450K USD value.

[Foundry Coke Producer Product Grading] Desafio: A producer required three distinct grades (por exemplo, large foundry lumps, small cupola nuts, brisa) but existing screens caused excessive breakage of fragile highcarbon coke.

[Solution HighQuality Coke Vibration Screen Implementation]: Installation of a doubledeck unit featuring lowstress vibration technology and polyurethane screens on the top deck.

[Resultados Resultados Quantificáveis]: Product degradation was minimized, improving the yield of premium large foundry lumps by over $200K annually per line.

7. CONSIDERAÇÕES COMERCIAIS

O preço do equipamento é escalonado com base no tamanho (área do convés), configuration complexity (número de baralhos), and selected materials specification:
Nível de serviço padrão: For lowercapacity lines (<500 MTPH), carbon steel construction with standard mesh panels.
Nível de serviço pesado: For primary sizing applications (>500 MTPH), featuring abrasionresistant liners at all impact points.
Nível Premium: Includes full stainlesssteel contact surfaces where corrosion resistance is critical.

Recursos opcionais incluem:
Advanced dust encapsulation systems
Variablefrequency drives (Inversores de frequência) para controle de movimento
Sensores de monitoramento de condição (temperatura do rolamento)
Sistemas de lubrificação automatizados

Service packages typically range from basic commissioning support through comprehensive multiyear maintenance agreements covering inspections and priority parts supply.

Financing options are available through partner institutions including equipment leasing structures that allow capital preservation while upgrading operations.

8.Perguntas frequentes

1º trimestre. Is this equipment compatible with our existing conveyor feed system?
Field data shows successful integration requires matching feed chute design to ensure even distribution across the full width of our vibrating screens’ inlet box.

2º trimestre. Qual é o impacto esperado no rendimento geral da nossa planta?
By virtually eliminating blindingrelated slowdowns these units maintain rated capacity consistently leading most plants report a net increase in average hourly output

3º trimestre. How does this solution handle variations in feedstock moisture content?
The adjustable vibration parameters allow operators compensate temporarily higher moisture levels preventing severe blinding until feedstock conditions normalize

4º trimestre. Quais são os prazos de entrega típicos para instalação?
Lead times vary model complexity but standard heavyduty units typically available within weeks following detailed application review confirm specifications

Q5. Quais condições comerciais são oferecidas?
We provide firm quotations valid days along detailed technical proposal Standard payment terms structured around milestones like order acceptance preshipment inspection completion commissioning

Q6. As peças de reposição estão prontamente disponíveis?
Critical wear parts like screen cloths specialized liners bearing assemblies held regional inventory ensure maximum uptime your operation

Q7. Que treinamento proporcionou à nossa equipe de manutenção operacional?
Comprehensive training covering safe operation routine adjustment procedures preventative maintenance checklist included scope commissioning