1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

На вашем предприятии по переработке кокса постоянно возникают узкие места и растут затраты на техническое обслуживание?? Для руководителей заводов и инженерных подрядчиков, неэффективный скрининг напрямую влияет на прибыль. Общие проблемы включают в себя:

Ослепление & Переноситься: Отлично, sticky coke particles blind screen decks, reducing effective screening area and forcing material carryover into the wrong product streams. This contaminates product grades and necessitates costly reprocessing.
Чрезмерное время простоя & Обслуживание: Traditional screens with complex drive mechanisms and numerous moving parts require frequent lubrication, belt changes, and bearing replacements, приводящие к незапланированным остановкам.
Высокое энергопотребление: Inefficient vibratory systems operate at constant high power, regardless of feed conditions, wasting significant energy over thousands of operational hours.
Структурная усталость & Failure: The intense, reciprocating forces from conventional exciters transmit high stress to the screen body and support structure, leading to weld cracks, side plate failures, and shortened equipment lifespan.

Are you seeking a coke vibration screen solution engineered to minimize these operational burdens while maximizing throughput and product consistency?

2. ОБЗОР ПРОДУКТА

Our engineered service provides heavyduty Coke Vibration Screens, specifically designed for the abrasive and demanding environment of coke handling in steel production, анодные установки, and calcining operations.

Операционный рабочий процесс:
1. Кормить & Распределение: Sized coke from crushers or ovens is fed onto the screen’s robust feed box for even distribution across the full width of the screening deck.
2. HighEfficiency Stratification: A powerful, linear vibratory motion stratifies the material bed, forcing fines downward through the screen media while conveying oversize toward the discharge end.
3. Точное разделение: Multiple deck configurations allow for precise separation into two or three distinct product streams (например, nut coke from breeze).
4. Контролируемый разряд: Separated fractions are discharged via dedicated chutes for downstream processing or stockpiling.

Область применения: Primary and secondary screening of metallurgical (met) coke, нефтяной кокс (нефтяной кокс), and calcined coke in sizing ranges typically from 080mm.

Ограничения: Not designed for extremely fine classification (<1мм) which requires specialized fine screening technology, or for materials at temperatures exceeding 250°C without specific design adaptations.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Модульная система палуб | Техническая основа: Independently tensioned polyurethane or wire cloth panels on a rigid subframe | Операционная выгода: Panels can be replaced individually without dismantling adjacent decks or extensive downtime. Damaged sections are isolated for quick changeout. | Воздействие на рентабельность инвестиций: Reduces deck replacement labor time by up to 60%, минимизация перерывов в производстве.

DualMass Vibrator Drive | Техническая основа: Two counterrotating eccentric masses generating a linear force along a defined stroke line | Операционная выгода: Transmits dynamic forces internally within the vibrator assembly rather than to the screen body and support structure. Starts smoothly under full load. | Воздействие на рентабельность инвестиций: Cuts structural maintenance costs by up to 40% and extends overall screen frame life by years.

Huck Bolt® Frame Construction | Техническая основа: Highstrength aircraftstyle fasteners providing consistent clamp force across joints | Операционная выгода: Eliminates weld fatigue failures at critical stress points on side plates and cross members under continuous vibratory loading. | Воздействие на рентабельность инвестиций: Dramatically reduces risk of catastrophic frame failure, ensuring multiyear structural integrity with minimal intervention.

Частотно-регулируемый привод (ЧРП) Compatibility | Техническая основа: Integration with VFD controls to adjust motor speed (об/мин) | Операционная выгода: Operators can finetune vibration amplitude and material travel speed in response to changes in feed rate or moisture content to optimize efficiency. | Воздействие на рентабельность инвестиций: Enables energy savings during lower throughput periods and optimizes performance without mechanical adjustments.

DustEncapsulated Bearing Assembly | Техническая основа: Labyrinth seals combined with positivepressure purge systems on vibrator shaft bearings | Операционная выгода: Effectively excludes abrasive coke dust from critical bearing housings in a highparticulate environment. | Воздействие на рентабельность инвестиций: Extends bearing service life by 23x compared to standard seals, preventing a primary cause of drive failure.

AbrasionResistant Lining Packages | Техническая основа: Bolton wear liners made from AR400 steel or specialized ceramics at highimpact points (кормушка, разгрузочные губы) | Операционная выгода: Protects structural steel from direct abrasion, preserving base metal integrity. Liners are sacrificial components designed for easy replacement. | Воздействие на рентабельность инвестиций: Turns major plate repair projects into simple liner swaps, saving on both material costs and extended welding downtime.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Industry Standard Coke Screen Design | Наше решение для виброгрохота для кокса | Преимущество (% Улучшение) |
| : | : | : | : |
| Доступность / Время работы| ~9294%, factoring in monthly maintenance stops for lubrication & adjustments.| >96%, achieved through sealedforlife vibrators & reduced lubrication points.| +34% увеличенный срок изготовления |
| Deck Panel Change Time| 812 hours for full deck access & retensioning.| <4 hours via modular panel design & external tensioning system.| До 60% Быстрее |
| Потребление энергии на тонну| Fixed power draw regardless of load; оцененный 0.15 kWh/ton.| VFDoptimized operation reduces draw under partial load; среднее. 0.11 kWh/ton.| ~27% reduction possible |
| Ожидаемая продолжительность жизни подшипников| 1218 months in dusty conditions with standard seals.| 36+ months with multistage dust encapsulation systems.| +100% улучшение |
| Структурная усталостная долговечность| Major weld inspections/rework every 35 years due to stress cracking.| Huckbolted construction targets >10year frame life without major weld repair.| +100% улучшение |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Емкость / Рейтинг: Sizing capacities from 200 TPH превышает 2,500 TPH depending on model aperture size.
Требования к питанию: Drive motors ranging from 15 кВт до 75 kW per vibrator unit (typically dualdrive), compatible with 400/690VAC, 50/60Hz supply.
Характеристики материала:
Рамка & Боковые пластины: Highyield strength carbon steel (Q345B / A572 Grade 50 equivalent).
Deck Support Beams: Reinforced hollow section beams.
Параметры экрана мультимедиа: Натянутые полиуретановые панели (для долголетия), woven wire cloth (for sharpness of cut), punch plate (for heavyduty scalping).
Физические размеры: Ширина от 1,2 м до 3,6 м.; lengths from 4.8m to over 10m for multideck configurations.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 20°С до +45°С.; material temperature up to ~150°C standard (higher temp options available). Weather covers and dust enclosures are optional.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Steel Plant Blast Furnace Feed Preparation

Challenge A major integrated steel mill experienced frequent blinding on its primary nut coke screens due to residual moisture fines carryover was contaminating blast furnace burden impacting furnace efficiency
Solution Installation of two widebody Coke Vibration Screens featuring nonblinding polyurethane deck panels with a high open area percentage combined with an aggressive vibration stroke
Results Screening efficiency improved from ~85% to consistently above >94%. Product contamination was eliminated reducing blast furnace fuel rate by an estimated . Annual maintenance hours per screen were reduced by .

Petroleum Coke Calcining Plant

Challenge A calciner needed reliable classification of calcined petcoke into multiple product fractions but faced rapid wear on wire cloth decks requiring biweekly changes causing significant downtime
Solution Implementation of a tripledeck Coke Vibration Screen configured with an abrasionresistant ceramic feed liner package modular polyurethane decks on top/middle decks for durability longlife wire cloth on bottom deck
Results Deck life on top two decks extended sixfold bottom deck life doubled Total annual screeningrelated downtime was cut by Planned maintenance became predictable

ByProduct Coke Screening Station

Challenge An aging screening station suffered chronic structural cracks at welds leading emergency repairs every months The violent vibration also damaged surrounding infrastructure
Solution Replacement units featured our dualmass vibrator drive system Huck bolted frame construction significantly reducing dynamic forces transmitted into the support structure
Results No structural weld repairs have been required years postinstallation Vibration readings on the plant floor were reduced dB improving operator environment

КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Equipment pricing tiers are structured based on size capacity robustness:

Tier Basic Duty Units designed lower capacity standalone replacement applications Tier HeavyDuty Units feature all core advantages listed above standard Tier SevereDuty Units include premium materials upgraded liners additional reinforcements extreme environments

Optional Features Include variable frequency drives automated lubrication systems multiple deck configurations special chutework custom skid bases comprehensive dust encapsulation

Service Packages range from basic commissioning supervision annual health inspections full longterm service agreements covering parts labor predictive maintenance planning

Financing Options available through partner institutions include equipment leasing capital loans payasyousave models tied efficiency guarantees facilitating budget management

Часто задаваемые вопросы

What if my existing foundation cannot handle new vibration loads Our dualmass vibrator system transmits significantly lower dynamic forces foundations than traditional brute force designs Engineering review can confirm compatibility often eliminating need costly foundation upgrades

How does this design handle variations feed rate The linear motion is inherently stable under varying loads For optimal control pairing with an optional allows operators adjust stroke parameters realtime maintain peak efficiency despite feed fluctuations

Are spare parts readily available We maintain strategic inventory critical wear components like polyurethane panels tensioning hardware seal kits ensure availability minimize lead times unscheduled stoppages

What typical delivery lead time Standard designs have lead times weeks Customized configurations may require weeks Detailed project planning provided upon specification confirmation

Do you offer performance guarantees Yes we provide guaranteed capacity throughput based your specific material characteristics Guarantees cover mechanical performance first year operation terms outlined commercial agreement