Bespoke Coke Vibration Screen Fabricator
1. PAINPOINT driven اوپننگ
ڇا توهان جو ڪوڪ هينڊلنگ آپريشن متضاد پيداوار جي معيار کان متاثر آهي, حد کان وڌيڪ ڏنڊ جي نسل, ۽ غير منصوبه بند سار سنڀال? ڪوڪ اسڪريننگ جي نگراني ڪندڙ پلانٽ مينيجرز لاءِ, common challenges directly impact profitability and throughput:
پيداوار جي آلودگي & Rejections: Inefficient separation allows undersize fines to contaminate blast furnace feedstock or anodegrade product, leading to customer penalties and degraded metallurgical performance.
Premature Screen Deck Failure: The extreme abrasiveness of hot or cold coke accelerates wear on screen panels and support structures, بار بار سبب, costly replacements and production stoppages.
انڌو ڪرڻ & کڻندڙ: Sticky coke particles and moisture can blind screen apertures, while insufficient vibration leads to material carryover, drastically reducing effective screening capacity and classification accuracy.
ساخت جي ٿڪ & وائبريشن ٽرانسميشن: Poorly engineered vibratory motion transmits damaging harmonics to the base frame and surrounding infrastructure, risking longterm structural integrity.
Are you seeking a screening solution engineered not just to move material, but to precisely classify it while withstanding the punishing environment of coke handling? The right bespoke vibration screen is a capital investment in predictable grading and operational continuity.
2. پيداوار جو جائزو
A Bespoke Coke Vibration Screen is a heavyduty industrial screening machine specifically designed for the sizing, ڇڪڻ, or dedusting of metallurgical coke (cold or hot) ۽ پيٽروليم ڪوڪ. Engineered from the ground up for this application, it replaces generic screens that fail under abrasive loads.
آپريشنل ڪم فلو:
1. ڪنٽرول ٿيل فيڊ: Coke is introduced via a regulated feed chute onto the screen’s inlet section, distributing load across the full deck width.
2. تيز شدت جي جوڙجڪ: A precisely tuned vibratory mechanism (typically dual eccentric shaft or bruteforce design) imparts a linear or elliptical motion, aggressively stratifying material. Fines are forced downward to contact the deck.
3. قطعي جدائي: Stratified particles pass through accurately sized screen panel apertures (تار جال, polyurethane, يا سوراخ ٿيل پليٽ), separating into defined size fractions (مثال, +50ايم ايم, 50mm+25mm, 25ايم ايم).
4. موثر خارج ٿيڻ: Sized fractions discharge via dedicated chutes into separate collection conveyors or bins for downstream processing.
ايپليڪيشن جو دائرو: ميٽالرجيڪل ڪوڪ جي پرائمري ۽ سيڪنڊري اسڪريننگ (blast furnace foundry), anodegrade پيٽروليم ڪوڪ, calcined coke. Suitable for sinter feed preparation and coke breeze recovery.
حدون: Not designed for wet screening processes or as a replacement for crushers. Maximum feed temperature and particle size are defined by specific material specifications.
3. بنيادي خاصيتون
ماڊلر ڊيڪ سسٽم | ٽيڪنيڪل بنياد: Boltin panel subframes with tensioning rails | آپريشنل فائدا: Enables rapid changeover of worn screen media (<4 ڪلاڪ بمقابله. 12+), minimizing downtime for maintenance crews. | ROI اثر: Reduces labor costs per changeout by ~60% and increases annual available production time.
Hot Coke Design Package | ٽيڪنيڪل بنياد: Internal aircooled bearing housings & heatresistant seals | آپريشنل فائدا: Allows continuous operation with coke feed up to 250°C without bearing lubrication failure or seal degradation. | ROI اثر: Eliminates costly cooling periods before screening, increasing line throughput by maintaining process flow.
اينٽي بلائننگ & Wear Systems | ٽيڪنيڪل بنياد: Integrated ball tray decks or tensioned wire mesh with polyurethane cleaners | آپريشنل فائدا: Continuous microimpact dislodges sticky particles; wearresistant liners on decks/sideplates extend service life in highabrasion zones. | ROI اثر: Maintains nearoriginal capacity over longer campaigns; reduces consumable parts expenditure by 3040% سالانه.
Dynamically Tuned Vibratory Frame | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) بهتر دٻاء جي ورڇ & isolation spring system | آپريشنل فائدا: Contains vibratory forces within the screen body; minimizes harmful transmission to supporting structures (<90% isolation efficiency). | ROI اثر: Protects civil foundation investments and eliminates ancillary structural repairs.
Dust Encapsulated ڊيزائن | ٽيڪنيڪل بنياد: Gasketed covers & dusttight discharge spouts with inspection ports | آپريشنل فائدا: Contains coke dust at transfer points, improving site air quality and reducing housekeeping labor. | ROI اثر: Lowers environmental compliance risk and reduces cleanuprelated operational delays.
Condition Monitoring Prep | ٽيڪنيڪل بنياد: Preinstalled sensor pads (وائبريشن, گرمي پد) on bearings with external junction box | آپريشنل فائدا: Facilitates easy integration into predictive maintenance programs for early fault detection. | ROI اثر: تباهي واري بيئرنگ ناڪامي کي روڪي ٿو; enables planned shutdowns, avoiding 70+ hours of unplanned downtime per incident.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Generic Screen) | Bespoke Coke Vibration Screen Solution | فائدو (% سڌارو) |
| : | : | : | : |
| ڊيڪ پينل سروس زندگي| 36 months under abrasive load| 814 months with applicationspecific media| +130% جي طرف +150% |
| اسڪريننگ جي ڪارڪردگي| ~85% for 25mm separation| مسلسل >92% for same separation| +8% مڪمل فائدو |
| اسڪرين جي سار سنڀال لاءِ سالياني ڊائون ٽائم| 120180 ڪلاڪ (معائنو, تبديليون)| 4060 ڪلاڪ (ماڊلر ڊيزائن)| 65% گهٽتائي |
| توانائي واپرائڻ في ٽين اسڪرين| بيس لائين (100%)| اصلاح ٿيل ماس & ڊرائيونگ جي ڪارڪردگي| 15% گهٽتائي |
| بيئرنگ MTBF (ناڪامي جي وچ ۾ وچولي وقت)| ~12,000 hours in harsh service| >20,000 hours with cooling/sealing package| +67% سڌارو |
Screening Efficiency defined as ratio of correctly sized undersize material recovered vs. total undersize in feed.
5. ٽيڪنيڪل وضاحتون
ظرفيت جي درجه بندي: ماڊل تي منحصر; معياري حد کان 200 MTPH کان 1,200 بلڪ ڪوڪ جو MTPH (80 lbs/ft³).
ڊرائيو يونٽ: Dual eccentric shaft mechanism with greaselubricated spherical roller bearings. Alternative bruteforce designs available for highcapacity scalping.
بجلي جي گهرج: 15 kW کان 55 kW موٽر (400V/50Hz يا جيئن بيان ڪيل), IP66 rated.
ڇت جي جوڙجڪ: اڪيلو, ٻيڻو, or tripledeck layouts based on cut points.
اسڪرين ميڊيا جا اختيار: Highcarbon اسٽيل تار mesh (hotgalvanized), polyurethane modular پينل, perforated manganese steel plates.
اڏاوتي فريم: Heavyduty carbon steel plate construction with internal ribbing; shotblasted and coated with industrial epoxy paint system.
جسماني طول و عرض (Typical DoubleDeck): Length ~7m x Width ~2.5m x Height ~3m (excluding supports).
آپريٽنگ ماحول: 20 ° C کان + 50 ° C تائين محيطي درجه حرارت لاء ٺهيل; capable of processing material up to 250°C with hot package.
6. درخواست جا منظر
[Steel Mill Blast Furnace Feed] چيلنج: A major integrated steelmaker experienced high variability in blast furnace coke size fraction (50mm+25mm), leading to irregular gas flow and increased fuel rate penalties estimated at €500k annually.حل: Implementation of a tripledeck bespoke coke vibration screen with precise aperture control ahead of the furnace bins.نتيجا: Achieved consistent sizing with <3% deviation in target fraction; reduced furnace fuel rate by 2%. Payback period was under 18 months via fuel savings alone.
[پيٽروليم ڪوڪ ڪليننگ پلانٽ] چيلنج: Anodegrade calciner needed to remove all 8mm fines from final product but faced rapid blinding of standard screens from residual volatiles.حل: Installation of a bespoke linear motion screen featuring antiblinding ball trays and directheated deck panels.نتيجا: Sustained screening efficiency above 94%; eliminated manual deck cleaning shifts; increased saleable product yield by an estimated 4%.
7. تجارتي خيالات
Our Bespoke Coke Vibration Screens are offered in three primary tiers:
1. (بنيادي درجي): Standard Duty Screens, engineered core components with selectable media options—ideal for lowertonnage operations processing cooled coke.
2. (Recommended Tier): HeavyDuty Performance Screens, includes all core features listed above—the standard solution for most highvolume metallurgical applications requiring reliability.
3. (پريميئم ٽائر): SevereDuty Engineered Systems, includes full FEA analysis report customised feed/discharge hoods advanced instrumentation packages—specified for greenfield sites maximum operational data capture
Optional features include variable frequency drives process control integration custom skid bases extended warranty packages
Financing options include capital purchase lease agreements operating leases tailored support service packages provide scheduled inspections parts supply
8.FAQ
Q1 Is your bespoke vibration screen compatible existing conveyor feed hoppers
Our engineering team will review your existing layout interface drawings We design custom inlet transition sections flanges ensure a proper fit minimal retrofit required during installation
Q2 عام انسٽاليشن ڪميشننگ ٽائم لائن ڇا آهي
From arrival site mechanical installation electrical connection dry run commissioning typically requires days supervised our engineer Delivery lead times vary based specification
Q3 How does this equipment impact overall plant noise levels
Properly installed isolated screens operate within dB(اي) range at meter distance meeting typical industrial environmental standards Acoustic enclosures are available option where required
Q4 What are payment terms delivery
Standard terms progress payment upon order confirmation payment prior shipment balance due upon completion Factory Acceptance Test Major projects may qualify structured milestone payments
Q5 Do you provide wear parts ongoing technical support
We maintain comprehensive inventory critical wear parts offer guaranteed hour dispatch key components Support packages include remote diagnostics annual health checks technician dispatches
