Ce Marked Coke Vibration Screen Distributor
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Is Inconsistent Coke Sizing Costing You $50,000+ Per Shift in Rejects and Downtime?
In the metallurgical and petroleum coke processing industry, a single screen deck failure or a 2% deviation in particle size distribution can halt a calciner or disrupt a downstream anode plant. You face the daily challenges of:
- Blinding and Peening: چپڪندڙ, highmoisture coke fines clogging standard screens, reducing effective open area by up to 40%.
- ساخت جي ٿڪ: Constant highGforce vibration cracking welds on nonreinforced frames, leading to unplanned 12hour maintenance shutdowns.
- Inconsistent Cut Points: Inefficient stratification causing oversize material to contaminate fines, forcing recrushing cycles that waste energy and wear out crushers.
- حفاظت جي تعميل جا خطرا: Operating without proper CE certification exposes your plant to regulatory fines and liability for worker safety.
- بنيادي ماڊل (2deck, manual lube): $85,000 $110,000
- معياري ماڊل (3deck, auto lube, poly panels): $135,000 $175,000
- پريميئم ماڊل (4deck, auto lube, گرم ڊيڪ, ريموٽ نگراني): $195,000 $250,000
- Heated Screen Decks: +$18,000 (for highmoisture applications)
- Ball Tray Cleaning System: +$9,500 (for fine mesh, <3ايم ايم)
- Remote Vibration Monitoring System: +$12,000 (predictive سار سنڀال)
- Custom Chute Work & Support Steel: +$15,000 $30,000
- معياري وارنٽي: 2 years on mechanical components, 5 years on structural frame.
- توسيع سروس پلان (ESP): $8,500/سال (شامل آهي 2 سالياني چڪاس, priority parts delivery, 24hour phone support).
- Full Turnkey Installation: $25,000 $45,000 (including commissioning and operator training).
- نيٽ 30/60 شرطون for qualified buyers.
- Leasetoown options starting at $2,800/month for the Standard Model.
- Performancebased payment: 10% upfront, 90% upon achieving 90%+ screening efficiency guarantee.
Can your current screening equipment handle the abrasive, highimpact nature of green and calcined coke while maintaining a precise 6mm to 50mm separation? جيڪڏهن نه, your profit margin is being screened out.
پيداوار جو جائزو: The CE Marked Coke Vibration Screen Distributor
هي هڪ سخت فرض آهي, linearmotion vibratory screener specifically engineered for the classification and distribution of petroleum coke, دھاتي ڪوڪ, ۽ فائونڊري ڪوڪ. It is designed to handle hightonnage feed streams (تائين 500 ٽي پي ايڇ) while providing a precise, multideck separation.
آپريشنل ڪم فلو:
1. فيڊ داخلا: Raw coke enters the distributor via a chute, landing on a wearresistant feed box to disperse the material evenly across the full screen width.
2. Stratification: Highamplitude, lowfrequency vibration (700900 آر پي ايم) causes heavier, larger particles to rise to the top layer, while fines migrate to the bottom deck.
3. درجه بندي: Material passes through a series of polyurethane or heavyduty woven wire mesh decks (عام طور تي 24 ڊيڪ) for precise sizing (مثال, +50ايم ايم, 2550ايم ايم, 1025ايم ايم, 10ايم ايم).
4. ورهائڻ: Sized fractions are discharged through dedicated spouts, directly feeding downstream conveyors, storage bins, or calcining kilns.
5. Oversize Reject: وڏي پيماني تي مواد (+50ايم ايم) is directed to a crusher circuit or reject chute.
ايپليڪيشن جو دائرو: Ideal for green coke handling at refineries, calcined coke processing at anode plants, and blast furnace coke sizing at steel mills.
حدون: Not recommended for wet, sticky materials with >15% surface moisture without the addition of a heated deck or ball tray cleaning system.
بنيادي خاصيتون
HeavyDuty Exciter Assembly | ٽيڪنيڪل بنياد: Dualshaft, counterrotating gearbox | آپريشنل فائدا: Generates a linear stroke of 1014mm, ensuring deep bed stratification without vertical lift | ROI اثر: Reduces power consumption by 15% compared to circular motion screens, lowering annual energy costs by $8,000$12,000
CE Certified Structural Integrity | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) designed side plates with 10mm thick Strenx 700 اسٽيل | آپريشنل فائدا: Eliminates frame cracking under continuous 24/7 آپريشن | ROI اثر: Extends equipment lifespan to 15+ سال, reducing capital replacement costs by 30%
ماڊلر Polyurethane اسڪرين پينلز | ٽيڪنيڪل بنياد: Slotopening, abrasionresistant polyurethane (ساحل اي 90) | آپريشنل فائدا: Reduces blinding from coke fines; panels are interchangeable in 15 منٽ | ROI اثر: Increases screen deck life by 3x over woven wire, بچت $4,500 annually in mesh replacement and labor
Integrated Feed Distributor Box | ٽيڪنيڪل بنياد: Angled, replaceable AR400 steel liners | آپريشنل فائدا: Prevents material segregation at the feed point, ensuring even load distribution | ROI اثر: پاران اسڪريننگ جي ڪارڪردگي کي بهتر بڻائي ٿو 812%, reducing recirculating loads and energy waste
خودڪار لوڻ وارو نظام | ٽيڪنيڪل بنياد: Centralized grease manifold with programmable timer | آپريشنل فائدا: آپريٽر جي مداخلت کان بغير مسلسل بيئرنگ لوبريڪيشن کي يقيني بڻائي ٿي | ROI اثر: Extends bearing life by 2x, preventing catastrophic failures that cost $15,000+ in repairs and lost production
Vibration Isolation Base Frame | ٽيڪنيڪل بنياد: Steel coil springs with 95% اڪيلائي جي ڪارڪردگي | آپريشنل فائدا: Transmits less than 5 kN of dynamic force to the support structure | ROI اثر: Eliminates the need for expensive reinforced concrete foundations, بچت $20,000 in civil works per installation
مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Standard Screen) | CE Marked Coke Vibration Screen Distributor | فائدو (% سڌارو) |
| : | : | : | : |
| اسڪريننگ جي ڪارڪردگي (6mm cut) | 7580% | 9295% | +1520% |
| Deck Life (Polyurethane) | 69 مهينا | 1824 مهينا | +100150% |
| ساخت جي فريم وارنٽي | 1 سال | 5 سال (with FEA certification) | +400% |
| شور جي سطح 1m | 95 ڊي بي(اي) | 82 ڊي بي(اي) | 14% (safer for operators) |
| تبديليءَ جو وقت (ڊيڪ) | 4 ڪلاڪ (2man crew) | 45 منٽ (1man crew) | 81% |
| بجلي جو استعمال (في ٽون) | 0.8 kWh/ٽن | 0.55 kWh/ٽن | 31% |
ٽيڪنيڪل وضاحتون
| پيرا ميٽر | تفصيل |
| : | : |
| ماڊل | CVD2448 (2.4m x 4.8m) |
| ظرف | 250 500 ٽي پي ايڇ (depending on cut point) |
| Number of Decks | 2, 3, يا 4 (ترتيب ڏيڻ جي قابل) |
| اسڪرين ايريا | 11.5 m² per deck |
| Vibration Type | Linear Motion |
| فالج | 10 14 ايم ايم (ترتيب ڏيڻ وارو) |
| وائبريشن فریکوئنسي | 750 900 آر پي ايم |
| موٽر پاور | 2 x 15 ڪلواٽ (TEFC, IP55) |
| Material of Construction | Strenx 700 پاسي واري پليٽ, AR400 feed box |
| اسڪرين ميڊيا | Polyurethane (slot or square opening) |
| Operating Temperature | 20°C کان +80°C (ماحول) |
| وزن (لڳ ڀڳ) | 12,500 ڪلو |
| طول و عرض (ايل x ڊبليو x ايڇ) | 6.2m x 3.0m x 2.8m |
| سي اي سرٽيفڪيشن | ها (IN 12100, IN 602041) |
ايپليڪيشن منظرنامو
Green Coke Dewatering & Sizing at a Refinery
چيلنج: A Gulf Coast refinery was experiencing 30% downtime on their coke drum dewatering screens due to blinding from 8% نمي جو مواد. Oversize material was damaging downstream crushers.
حل: Installed a 3deck CE Marked Coke Vibration Screen Distributor with slotted polyurethane panels and a 12mm stroke.
نتيجا: Screening efficiency increased to 94%. Crusher wear life doubled. Unplanned downtime dropped from 120 hours/year to 12 ڪلاڪ / سال, بچت $180,000 گم ٿيل پيداوار ۾.
Calcined Coke Classification for Anode Production
چيلنج: An aluminum smelter needed a precise 0.5mm to 6mm fraction for anode paste. Their existing screens produced high variability (+/ 1.5ايم ايم), causing anode quality issues.
حل: Deployed a 4deck unit with a dedicated feed distributor to ensure even material spread.
نتيجا: Particle size distribution tightened to +/ 0.3ايم ايم. Anode rejection rate fell from 4% جي طرف 0.5%. The ROI was achieved in 11 months due to reduced scrap and rework costs.
Blast Furnace Coke Screening at a Steel Mill
چيلنج: A steel mill required a consistent +25mm fraction for their blast furnace. Their existing screens were structurally failing after 3 years due to high Gforces.
حل: Replaced with a CEcertified unit featuring a heavyduty FEAdesigned frame and 5year structural warranty.
نتيجا: Structural integrity issues eliminated. The +25mm fraction consistency improved to 98%. پلانٽ حاصل ڪيو الف 15% ڪوڪ جي شرح ۾ گهٽتائي (kg coke per ton of iron) due to better burden permeability.
تجارتي خيالات
سامان جي قيمت جا درجا (FOB, ExWorks):
اختياري خاصيتون:
سروس پيڪيجز:
فنانسنگ جا اختيار:
FAQ
1. What is the maximum moisture content this screen can handle for green coke?
The standard unit handles up to 12% surface moisture. For moisture levels between 12% ۽ 18%, we recommend the optional heated deck system to prevent blinding. Above 18%, a thermal drying step is advised before screening.
2. How does the CE certification impact my plant’s safety compliance?
The CE mark certifies compliance with the EU Machinery Directive (2006/42/اي سي). This includes a full risk assessment, safety circuit design, and documentation. For plants in regulated jurisdictions, this reduces liability and simplifies safety audits.
3. Can this screen be retrofitted into my existing support structure?
ها. The vibration isolation base frame transmits less than 5 kN of dynamic force. Most existing steel structures rated for 10 kN can support this unit without reinforcement. We provide a free structural load analysis with a purchase order.
4. What is the typical lead time for a custom configuration?
Standard models ship in 810 هفتا. Custom configurations (مثال, specific deck angles, special materials) require 1216 هفتا. We offer expedited production for an additional 15% fee, reducing lead time to 6 هفتا.
5. How do I change the cut point for a different product specification?
Cut points are changed by swapping the polyurethane screen panels. A 2man crew can change a full deck in under 45 منٽ. We stock over 50 standard opening sizes (0.5mm to 100mm) for immediate shipment.
6. What is the expected annual maintenance cost?
Annual maintenance costs average $4,000 $6,000. This includes bearing grease (every 40 ڪلاڪ), polyurethane panel replacement (every 1824 مهينا), and exciter gearbox oil changes (every 2,000 ڪلاڪ). The automatic lubrication system reduces labor costs by 60%.
7. ڇا توهان ڪارڪردگي جي ضمانت فراهم ڪندا آهيو?
ها. We guarantee a minimum screening efficiency of 90% for your specified cut point (based on a representative material sample). If the unit fails to meet this benchmark after commissioning, we will adjust the stroke, زاويه, or deck configuration at no cost.
