Coke Vibration Screen ODM Manufacturer
1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT
Is your coke handling operation plagued by persistent bottlenecks, чрезмерные затраты на техническое обслуживание, и нестабильное качество продукции? Для руководителей предприятий, контролирующих сортировку кокса, common challenges directly impact the bottom line:
Ослепление & Время простоя: Отлично, влажные частицы кокса прилипают к ситам, вызывая быстрое ослепление. This reduces effective screening area by up to 40%, forcing frequent shutdowns for manual cleaning and slashing throughput.
Преждевременный износ & High OPEX: The abrasive nature of metallurgical coke accelerates wear on screen panels, палубы, и возбудители. Unplanned component replacements and associated labor can increase annual maintenance budgets by 25% или больше.
Неэффективное отделение мелочи: Inadequate vibration dynamics lead to poor segregation of breeze (coke fines under 10mm). This results in product contamination, lost revenue from missized material, and potential downstream process issues.
Структурная усталость & Vibration Transmission: High Gforces needed for effective screening transmit damaging vibrations to the support structure and surrounding equipment, leading to cracks, foundation issues, and safety concerns.
Are you searching for a robust screening solution that delivers consistent uptime, lowers total cost of ownership, and ensures precise size separation for your coke product?
2. ОБЗОР ПРОДУКТА
The Coke Vibration Screen is a heavyduty industrial screening machine engineered for the highcapacity sizing and scalping of metallurgical coke in battery, quenching, and sorting stations. Its core function is to separate crushed coke into precise fractions (например, доменный кокс, ореховый кокс, ветер) while efficiently removing fines.
Операционный рабочий процесс:
1. Кормить & Распределение: Crushed coke is uniformly fed onto the inlet end of the inclined screen deck via a chute or feeder.
2. Стратификация & Разделение: Высокая интенсивность, linear or elliptical vibration stratifies the material bed. Smaller particles pass through precisely sized deck apertures; oversized particles travel across the deck surface.
3. Увольнять: Correctly sized fractions are discharged via separate outlets—oversize to crushers for recirculation or as product, undersize as breeze or product—ensuring a clean separation.
Область применения: Primary sizing of metallurgical coke after crushing; scalping of oven discharge; dedusting and fines removal; recovery operations.
Ограничения: Not designed for sticky materials without specialized deck technology; maximum feed size is constrained by deck opening and machine design; requires controlled feed rate for optimal efficiency.
3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ
Система палубы HeavyDuty | Техническая основа: Modular polyurethane or rubberclad steel panels with reinforced fixing | Операционная выгода: Dramatically increased service life under abrasive conditions; reduced noise levels (by ~10 dBA); panels are easily replaced in sections minimizing downtime | Воздействие на рентабельность инвестиций: Cuts panel replacement costs by up to 60% over traditional woven wire decks.
AntiBlinding Technology | Техническая основа: Integrated ball tray decks or ultrasonic screen mesh cleaning systems | Операционная выгода: Continuous microimpact dislodges lodged particles near aperture openings maintaining nearoriginal open area | Воздействие на рентабельность инвестиций: Sustains design capacity throughput reduces cleaning downtime by over 70%.
Balanced Elliptical Vibration | Техническая основа: Twin shaft exciter with outofphase synchronized weights generating an elliptical throw pattern | Операционная выгода: Optimized material travel speed with sharp stratification enhances separation accuracy especially for midrange sizes (1030мм) | Воздействие на рентабельность инвестиций: Improves product purity by an average of 15% reducing recrush load and maximizing premium fraction yield.
Закрытая пыленепроницаемая конструкция | Техническая основа: Gasketed side plates and dust hood connections with integral skirt boards | Операционная выгода: Contains airborne coke dust at transfer points improving site air quality meeting environmental standards | Воздействие на рентабельность инвестиций: Lowers housekeeping costs mitigates health safety risks avoids potential regulatory noncompliance fines.
Изолированная вибрационная рамка | Техническая основа: Dynamic vibration isolators (rubber or spring) between the vibrating body and stationary base frame | Операционная выгода: Поглощает 95% of dynamic forces preventing transmission to supporting structures eliminates fatigue failures | Воздействие на рентабельность инвестиций: Removes need for massive dedicated foundations reduces installation time capital cost protects plant infrastructure integrity.
Centralized Greasing Lube System | Техническая основа: Manifold with lines feeding all major bearing points from a single access port | Операционная выгода: Enables safe rapid lubrication during brief pauses extends bearing life under highload hightemperature conditions | Воздействие на рентабельность инвестиций: Standardizes preventive maintenance intervals reduces bearing failure rates by an estimated 40%.
4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА
| Метрика производительности | Отраслевой стандарт | Решение для вибрационного грохота кокса | Преимущество (% улучшение) |
|||||
| Deck Panel Lifespan | Woven wire mesh lasts 23 месяцев в условиях сильного истирания | Polyurethaneclad modular panels last 812 месяцы | +300% срок службы |
| Эффективность скрининга | ~85% efficiency for midsize separation due to blinding | Поддерживает >92% efficiency via antiblinding systems | +78% устойчивая эффективность |
| Время простоя при техническом обслуживании | 812 hours monthly for cleaning bearing checks panel replacement
| Energy Consumption per Ton ~0.12 kWh/ton processed
| Breeze (10мм) Contamination in Product Fraction
5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ
Емкость / Рейтинг: Модельзависит от 200 TPH превышает 1500 TPH throughput capacity standard designs available
Требования к питанию: Drive motor range from 7.5 кВт до 45 kW depending on screen size mass excitation force
Характеристики материала: Highstress frame components S355JR steel side plates wear liners Hardox®400 Abrasionresistant polyurethane rubber composite deck materials
Физические размеры (Типичная модель): Deck Size (ДхШ): 3m x1 .5m Overall length:~4 .2m Overall width:~2 .8m Height:~1 .6m Weight:~6500kg
Экологический рабочий диапазон: Температура окружающей среды:20°C +50°C Feed material temperature upto120°C(Макс) Weather protection IP65 enclosure optional
6. СЦЕНАРИИ ПРИМЕНЕНИЯ
Metallurgical Coke Plant Blast Furnace Feed Preparation Challenge:: Existing screens blinded within hours due high moisture content in quenched coke causing severe bottleneck before furnace feed bins resulting in inconsistent size distribution affecting furnace efficiency
Решение:: Installation two large doubledeck Coke Vibration Screens equipped ball tray antiblinding decks isolated base frames
Результаты:: Screening availability increased from94%. Blast furnace feed consistency improved quantified as+/5mm size variation reducedby30%. Annual maintenance labor hours decreasedby1200
Coke Sorting Terminal Product Diversification Challenge:: Terminal needed produce three distinct saleable products(>50mm2550mm<25мм)from single feed stream but existing separator generated excessive fines(<10мм)in midrange fraction reducing its market value
Решение:: Implementation multislope Coke Vibration Screen with precision elliptical vibration finetuning deck tensioning system
Результаты:: Product purity each fraction achieved>95%. Revenue from midrange(2550мм)fraction increasedby18%due reduced fines content System handled variable feed rates without performance degradation
7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ
Ценовые уровни оборудования: Entrylevel standard duty screens(starting~$25000);Heavyduty customengineered units($65000$200000+)based size configuration options
Дополнительные функции / Обновления: Stainless steel construction critical areas hotmaterial handling kits spray bar systems different deck types(harps tensioned polyurethane etc.) variable frequency drives advanced condition monitoring sensors
Пакеты услуг: Tiered annual maintenance contracts covering inspection parts discounts priority support Extended warranty available upto36months Comprehensive training programs operational maintenance staff included
Financing Options Available through partners include equipment leasing longterm rental purchase plans tailored capital expenditure cycles Project financing considered largescale installations
8. Часто задаваемые вопросы
Q1 How do we determine correct screen size deck configuration our specific capacity requirements?
Our engineering team requires your detailed feed rate particle size distribution(P80 D50)desired product splits moisture content This data allows us model recommend optimal machine specifications guarantee performance
Q2 Can this equipment integrate our existing PLC control system material handling network?
Yes standard designs include control panel compatible common industrial protocols(Profibus Ethernet/IP etc.) We provide necessary interface documentation facilitate integration your plant SCADA system
Q3 What typical installation timeline foundation requirements?
With isolated design foundation requirements less stringent than older screens Typical installation including positioning electrical mechanical connection commissioning takes510working days depending complexity Preinstallation foundation drawings issued advance
Q4 Are spare parts readily available what expected lead times?
We maintain strategic inventory critical wear parts(decks bearings exciters)at regional hubs Standard parts ship within48hours Custom components have lead times communicated upfront during purchase Longterm supply agreements ensure ongoing support
Q5 How does equipment handle variations feed rate material composition?
Robust design accommodates reasonable fluctuations Variable speed drive option allows operators adjust vibration intensity optimize performance realtime changing conditions ensuring consistent output quality