1. ABERTURA ACIONADA POR PAINPOINT

Are your coke screening operations plagued by persistent, ineficiências dispendiosas? Plant managers and engineering contractors face significant challenges in maintaining consistent product quality and throughput. Os pontos problemáticos comuns incluem:
Cegagem & Transferir: Moisture and fine particles adhere to screen decks, blinding apertures and forcing material carryover. This results in offspec product, increased recrushing loads, and wasted yield.
Tempo de inatividade excessivo & Manutenção: Frequent screen cloth changes and structural repairs due to aggressive vibration or material abrasion halt your production line, impactando diretamente seus resultados financeiros.
Dimensionamento inconsistente & Perda de rendimento: Ineffective screening leads to missized coke fractions, compromising blast furnace efficiency for your customers and eroding your profit margins.
Altos custos operacionais: Premature component failure, high energy consumption from inefficient drives, and laborintensive cleaning procedures inflate your costperton.

Is there a screening solution engineered to withstand the abrasive nature of metallurgical coke while delivering precise separation with maximum uptime?

2. VISÃO GERAL DO PRODUTO

The ISOCertified Coke Vibration Screen is a heavyduty linear or elliptical motion vibrating screen specifically engineered for the dry separation of metallurgical coke into precise size fractions (por exemplo, coque de alto forno, coque de nozes, brisa). Its robust design addresses the unique abrasiveness, densidade, and size range of coke particles.

Fluxo de Trabalho Operacional:
1. Alimentar & Distribuição: Sized coke from crushers is evenly distributed across the full width of the screen’s feed box.
2. Estratificação & Separação: HighGforce vibration stratifies material; fines pass through the configured screen cloth apertures while oversize travels toward the discharge end.
3. Descarga: Correctly sized fractions are discharged into separate chutes or conveyors for stockpiling or shipment.

Escopo de aplicação: Primary and secondary screening of metallurgical coke in coke plants, siderúrgicas, e terminais de movimentação de granéis. Ideal for sizing ranges from 80mm down to 05mm breeze.

Limitações: Not designed for wet screening applications or for materials with extreme temperature (>150°C) without specific modifications.

3. RECURSOS PRINCIPAIS

Sistema de suporte de convés para serviços pesados | Base Técnica: Reinforced crossmembers with rubber buffer pads | Benefício Operacional: Eliminates direct metaltometal contact, drastically reducing noise (<85dB) and dissipating destructive harmonic vibrations | Impacto do ROI: Extends screen cloth and structural life by up to 40%, reducing part replacement costs and downtime.

Painéis modulares de tela de poliuretano | Base Técnica: Abrasionresistant PU with reinforced steel backing | Benefício Operacional: Highly resistant to wear from sharp coke edges; antiblinding properties reduce pegging | Impacto do ROI: Panel service life is 35x longer than wire mesh, lowering consumable inventory costs and changeout labor.

DualVibration Motor Drive System | Base Técnica: Two synchronized externally mounted motors generating linear motion | Benefício Operacional: Simplified maintenance; no complex gearboxes or driveshafts; fácil ajuste de amplitude | Impacto do ROI: Proven motor reliability reduces drive system failures; energyefficient design cuts power consumption per ton screened.

Total Enclosure Dust Containment Skirt | Base Técnica: Multistage rubber sealing system around deck perimeter | Benefício Operacional: Effectively contains coke dust at transfer points, melhorando a segurança do local e a conformidade ambiental | Impacto do ROI: Minimizes material loss as product dust and reduces housekeeping labor requirements.

QuickRelease Tensioning System for Screen Cloths | Base Técnica: Lateral tensioning rails with simple bolt mechanisms | Benefício Operacional: Enables singleoperator screen panel change in under 30 minutes versus industrystandard hours | Impacto do ROI: Directly increases plant availability by minimizing planned maintenance windows.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Typical Coke Screen) | ISOCertified Coke Vibration Screen Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Vida útil do pano de tela | 23 months with wire mesh panels | 812 months with modular PU panels | +300% vida útil |
| Disponibilidade Anual| ~92% (700+ horas de inatividade) | >96% (<350 horas de inatividade) | +4% absolute availability |
| Sizing Accuracy| ~9092% efficiency (varies with moisture)| >95% consistent efficiency (antiblinding design) | +35% ganho de eficiência |
| Noise Emission| Muitas vezes excede 90 dB(UM) no 1 medidor| Mantém <85 dB(UM) no 1 medidor| Redução significativa na exposição ao ruído |
| Consumo de energia| Baseline per ton processed| Até 15% menor kWh/ton (optimized drive/mass)| 15% custo operacional |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Disponível em larguras de 1,2m a 3,6m; comprimentos de 4,8m a 10m. Capacidades de 200 acabar 1500 toneladas métricas por hora, depending on aperture size and feed gradation.
Requisitos de energia: Motores de vibração dupla variando de 2 x 7.5 kW para 2 x 45 kW (400V/50Hz ou conforme especificado). Total installed power depends on machine size and mass.
Especificações de materiais: Quadro principal: Aço estrutural S355JR. Estruturas de convés: Hardox® wear plate or equivalent on critical areas. Painéis de tela: Customizable polyurethane or rubber compounds for required cut point.
Dimensões Físicas & Massa: Varia significativamente por modelo. Exemplo (Medium Duty): Width=2.4m, Length=6m; Approximate Mass=8,500 kg excluding motors.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C. Bearings rated for continuous operation up to +120°C surface temperature.

6. CENÁRIOS DE APLICAÇÃO

[Usina Siderúrgica Integrada] Desafio: A major steel producer faced consistent yield loss due to fine coke (<10milímetros) contaminating blast furnacegrade fraction (+25milímetros). Manual cleaning of blinded wire mesh screens was required weekly.

[Produtor Comercial de Coca-Cola] Desafio: A merchant plant needed to increase throughput after a crusher upgrade but was bottlenecked by an older screening stage that could not handle the increased load without excessive carryover.

[Solução:] Implementation of a primaryclassifying ISOCertified Coke Vibration Screen fitted with multislope PU panels on the top deck.

[Resultados:] Sizing accuracy improved from ~88% to over 96%. Blindingrelated stoppages were eliminated.

[Solução:] Installation of two widebody linear motion screens in parallel for load distribution.

[Resultados:] Screening capacity matched crusher output at over 800 tph per line.

7. CONSIDERAÇÕES COMERCIAIS

Our ISOCertified Coke Vibration Screens are offered in three primary tiers:

Nível de serviço padrão: For lowercapacity lines (<400 tph), featuring robust construction with standard wear liners.
Nível de serviço pesado (Mais Comum): Inclui todos os recursos principais listados acima (PU panels, quickrelease systems), designed for mainline primary/secondary screening.
Nível Premium: Includes full instrumentation (sensores de monitoramento de vibração), sistemas de lubrificação automatizados, and special coatings for highly corrosive environments.

Optional features include stainless steel components for specific zones, custom feed boxes/hoppers, spray bar systems for controlled dust suppression during transfer.

We offer comprehensive service packages ranging from annual inspections with condition reports to full longterm maintenance agreements including parts supply.

Flexible financing options are available through our partners including equipment leasing programs tailored for capital expenditure cycles common in mineral processing industries.

8.Perguntas frequentes

Q1 – Are these screens compatible with our existing feed conveyor discharge heights?
A1 – Our engineering team designs each unit based on your specific layout data provided during quotation including feed height clearances ensuring seamless integration into your current flow sheet without major structural modifications required onsite

Q2 – What is the expected operational impact during installation?
A2 – We provide detailed installation plans requiring typically a fivetosevenday shutdown window depending on foundation preparation requirements performed beforehand by your team

Q3 – How does this solution handle variations in feed moisture content?
A3 – The combination of high Gforce vibration antiblinding panel technology allows effective stratification even with moderate surface moisture Field data shows consistent performance upto four percent surface moisture beyond which predrying is recommended

Q4 – What are typical commercial terms lead time payment structure?
A4 – Standard lead times range between twelvesixteen weeks exworks Payment terms are generally structured as thirty percent upon order sixtyfive percent before shipment five percent after commissioning

Q5 – Do you provide performance guarantees?
A5 – Yes we guarantee mechanical performance against agreed specifications including capacity sizing accuracy under defined feed conditions These are detailed within our commercial proposal

Q6 – Who handles installation supervision commissioning?
A6 – We offer optional expert site supervision commissioning services as part of our technical package ensuring optimal startup performance knowledge transfer directly onto your operating maintenance teams

Q7 – Can we retrofit certain features like quickrelease tensioning onto our existing screens?
A7 – In many cases yes Our service division conducts audits provides retrofit kits modernize older equipment extending its life improving maintainability often providing strong returnoninvestment versus complete replacement