1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Есть ли на вашем предприятии по переработке кокса постоянные узкие места?, начисление чрезмерных штрафов, и незапланированные затраты на техническое обслуживание? Неэффективный скрининг напрямую влияет на вашу прибыль из-за потери продукта., повышенное потребление энергии для последующих процессов, и дорогостоящие простои из-за замены сит. Вы сейчас сталкиваетесь:

Перенос высоких штрафов: Ineffective separation leading to valuable coke breeze contaminating the product stream, reducing overall yield and saleable tonnage.
Frequent Screen Blinding & Время простоя: Moisture and sticky fines clogging screen apertures, requiring frequent shutdowns for manual cleaning or deck replacement, остановка всей вашей технологической линии.
Чрезмерный износ оборудования: Uncontrolled vibration and impact from oversized material or poor feed distribution accelerating wear on screen panels, опорные структуры, and springs.
Непоследовательная оценка продукта: Fluctuating feed rates or improper screening action resulting in offspec product that fails to meet stringent customer or internal blast furnace specifications.
Высокие эксплуатационные расходы: The cumulative effect of these issues—lost production, высокие трудозатраты на техническое обслуживание, and premature component failure—erodes plant profitability.

The solution lies in specifying a vibration screen engineered explicitly for the abrasive, highimpact demands of coke classification. The right equipment transforms these operational challenges into controlled efficiency.

2. ОБЗОР ПРОДУКТА

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the precise size separation of metallurgical coke and coke breeze. Its primary function is to ensure a clean, onspec product while maximizing throughput and minimizing fines loss.

Операционный рабочий процесс:
1. Контролируемая подача: Sized coke from the crusher or cooler is delivered onto the screen via a regulated feed box to ensure even distribution across the full width of the screening surface.
2. HighIntensity Separation: A robust vibrator assembly (exciters or unbalanced motors) imparts a linear or elliptical motion to the screen box. This action stratifies the material, forcing undersize particles (коксовая мелочь) through the defined screen panel apertures.
3. Positive Material Discharge: Негабаритный материал (продуктовый кокс) travels along the deck length and discharges at the end of the screen, while undersize material is collected in a hopper beneath the decks for separate conveyance.

Область применения & Ограничения:
This equipment is specifically designed for hot or cold coke sizing in coke handling plants, системы загрузки доменной печи, and anode production facilities. It is not suitable for wet screening applications without significant modification or for processing materials with drastically different bulk densities and abrasiveness without a full engineering review.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Система поддержки палубы HeavyDuty | Техническая основа: Reinforced crossmembers with bolted, modular panel attachment | Операционная выгода: Eliminates panel flexing and fatigue failure under heavy load; allows for rapid, individual panel replacement without welding | Воздействие на рентабельность инвестиций: Сокращает время простоя при смене колоды до 60% по сравнению со сварными системами.
Технология AntiBlinding Deck | Техническая основа: Polyurethane or rubberclad screen panels with flexible, самоочищающиеся отверстия | Операционная выгода: Minimizes adhesion of moist fines; panels flex with each vibration cycle to dislodge trapped particles | Воздействие на рентабельность инвестиций: Maintains consistent throughput and grading quality, reducing cleaning shutdown frequency.
DualVibrator Synchronization | Техническая основа: Two externally mounted exciters synchronized via a gear coupling drive | Операционная выгода: Обеспечивает стабильную, linear vibration force across the entire screen box width; allows for easy adjustment of amplitude | Воздействие на рентабельность инвестиций: Ensures uniform screening efficiency and extends bearing life through balanced load distribution.
SubResonant Spring Isolation | Техническая основа: Screen box mounted on highcycle composite rubber springs or steel coil springs tuned below resonance frequency | Операционная выгода: Изолирует до 95% динамических сил от несущей конструкции; allows installation on elevated platforms without major structural reinforcement | Воздействие на рентабельность инвестиций: Lowers installation costs and prevents vibration damage to surrounding infrastructure.
Пакет устойчивых к истиранию подкладок | Техническая основа: Wear plates lined with AR400 steel at all critical impact points (кормушка, разгрузочные губы) | Операционная выгода: Protects the main screen body from direct abrasion by coarse coke | Воздействие на рентабельность инвестиций: Extends structural life of the main asset by years, deferring major capital expenditure.
Enclosed Dust Sealing System| Техническая основа: Continuous rubber sealing strips between decks and around access doors| Операционная выгода: Contains dust emissions at transfer points for a cleaner, safer working environment| Воздействие на рентабельность инвестиций: Reduces housekeeping labor and aids in compliance with plant environmental standards.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт | Решение для вибрационного грохота кокса | Преимущество (% улучшение) |
| : | : | : | : |
| Deck Panel Service Life | 36 месяцы (standard steel) | 918 месяцы (modular polyurethane/AR combo) | +100% к +200% |
| Эффективность скрининга (for target size)| ~8590% | Последовательный 9396% efficiency maintained over time due to antiblinding tech| +5% абсолютный выигрыш |
| Annual Downtime for Screen Maintenance| 80120 часов/год (уборка & changes) | 3050 часов/год (modular changes only)| ~60% снижение |
| Vibration Transmission to Structure| Значительный; often requires stiffening| Минимальный (90% isolation |
| Amplitude Adjustment Process| Requires adding/removing eccentric weights; downtime needed| External adjustment via variable counterweights or motor speed control; operational adjustment possible.| Time savings >75% per adjustment |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Емкость & Рейтинг: Разработан для пропускной способности от 50 ТПХ до 1,200+ TPH depending on model size and aperture selection.
Требования к питанию: Приводится в движение двойными вибраторными двигателями, начиная от 2 х 7.5 кВт до 2 х 45 кВт (400/690В, 50/60Гц). Drive motor requirements vary by model.
Характеристики материала: Main frame Carbon steel (СТ37). Wear surfaces Replaceable AR400 steel liners. Screen panels Modular polyurethane rubber tensioned panels OR perforated steel plate panels with abrasionresistant treatment.
Физические размеры: Одинокий, двойной, или трехъярусные конфигурации доступны. Typical widths from 1.2m to 3.6m; lengths from 4m to 10m inclusive of feed/discharge boxes.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°С до +50°С.. Handles material temperatures up to ~150°C continuously with appropriate component specifications.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Blast Furnace Coke Screening Plant

Challenge A major integrated steel mill experienced excessive fines (<10мм) in their blast furnace feed stock due to degraded screenscreen decks blinding daily through moisture ingress causing inconsistent sizing that risked furnace permeability
Solution Installation of two tripledeck Coke Vibration Screens featuring selfcleaning polyurethane panels on top/middle decks combined with high open area wire mesh bottom decks
Results Achieved consistent product grading with <2% fines carryover eliminated two daily manual cleaning shifts reduced annual maintenance hours by over four hundred

Coke Breeze Recovery Circuit

Challenge An independent coke producer was losing significant revenue as valuable breeze was being misdirected into waste streams due an inefficient singledeck vibrating screen
Solution Implementation of a dedicated doubledeck fine Coke Vibration Screen equipped with specialized ball tray decks prevent blinding on fine mesh apertures
Results Recovered an additional metric tons per hour saleable breeze increasing annual revenue by over fifteen percent achieving full payback within eight months

Anode Grade Coke Sizing

Challenge A carbon plant required extremely tight particle size distribution control but their existing screens produced excessive attrition generating unwanted ultrafines during classification process
Solution Commissioning customengineered lowattrition linear motion Coke Vibration Screens featuring gentle material handling low stroke/highfrequency design combined cascading deck arrangement
Results Reduced generation minus fraction by thirty percent while meeting stringent topsize cut point specification improving downstream paste mixing consistency

КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Pricing tiers are primarily determined by machine size deck count features:
Base Model Tier Standard duty construction fixed amplitude vibrators conventional steel panels suitable lower capacity replacement applications
Performance Tier Includes antiblinding decks adjustable amplitude vibrators composite spring isolation extended wear linings recommended new installations major upgrades
Premium Tier Full custom engineering including special materials dust suppression hoods advanced monitoring sensors predictive maintenance integration

Optional Features Include spray systems dust encapsulation covers variable frequency drives remote monitoring kits different panel types access platforms walkways

Service Packages Available as factory commissioning multiyear parts kits annual inspection contracts full maintenance agreements ensuring operational readiness

Financing Options Flexible acquisition models include outright purchase capital lease operating lease structures tailored support project financing large capital projects

Часто задаваемые вопросы

What is typical lead time delivery new Coke Vibration Screen?
Lead times vary based complexity customization standard designs typically available within weeks fully customized units may require months detailed engineering fabrication commence upon order approval

Can this equipment integrate existing conveyor feed system?
Yes screens are engineered accept standard belt conveyor feeds require properly designed feed box ensure even distribution across full width maximize efficiency prevent localized wear

How does power consumption compare older screening equipment?
Modern designs focus energy efficiency direct drive exciters premium efficiency motors typically result similar marginally lower consumption compared older units while delivering significantly higher throughput reliability

What key factors determining correct screen size my application?
Primary factors are total required tonnage per hour desired separation sizes percentage open area selected panels material bulk characteristics consultation application engineer essential specify correctly

Доступны ли запасные части?
Manufacturers maintain comprehensive inventory critical wear parts vibrator assemblies springs panel modules ensuring availability minimize potential extended downtime events