Coke Vibration Screen Manufacturer Testing
1. PAINPOINT driven اوپننگ
Is your coke screening operation plagued by persistent, costly inefficiencies? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, the challenges of screening bulk metallurgical coke directly impact throughput, پيداوار جي معيار, and bottomline profitability. عام آپريشنل رڪاوٽون شامل آهن:
انڌو ڪرڻ & کڻندڙ: Fine coke breeze and moisture cause screen mesh blinding, reducing effective screening area. گڏوگڏ, undersize material carries over with the product stream, contaminating blast furnace feed and degrading its performance.
اضافي سار سنڀال Downtime: The abrasive nature of coke accelerates wear on screen decks, پاسي واري پليٽ, and exciters. Frequent component replacement leads to unplanned downtime and high spare parts inventories.
غير موثر جزا جدا ڪرڻ: Inadequate separation of the 010mm fraction results in lost revenue from breeze sales and inefficient recycling within the coke plant.
Structural Fatigue & Failure: High Gforces from traditional vibrators transfer damaging stress to the screen body and support structure, leading to weld cracks and catastrophic frame failures.
اعلي توانائي واپرائڻ: Inefficient drive systems and oversized motors run continuously, contributing to significant, nonproductive power costs.
Are you seeking a solution that reduces downtime by 30% or more while ensuring consistent product sizing? The answer lies in selecting a coke vibration screen engineered specifically to overcome these materialspecific challenges.
2. پيداوار جو جائزو
The equipment in focus is a heavyduty Coke Classification Vibrating Screen, designed for highcapacity sizing of hot or cold metallurgical coke (25mm 80mm) from oven discharge and the subsequent separation of coke breeze (0mm 10mm).
آپريشنل ڪم فلو:
1. کاڌو & ورهائڻ: Bulk coke is uniformly fed onto the robust feed box, which distributes the material across the full width of the primary screen deck.
2. پرائمري سائيز: A highstrength wire mesh or punch plate deck performs the primary separation, allowing undersize material (breeze and small fractions) to pass through.
3. ثانوي اسڪريننگ & ڏنڊ هٽائڻ: A second deck further refines the separation, ensuring maximum recovery of marketable coke breeze.
4. خارج ٿيڻ: Correctly sized foundry or blast furnace coke discharges from the screen end, while separated fines are collected via a dedicated chute for processing or sale.
ايپليڪيشن جو دائرو & حدون:
This equipment is designed for dry or slightly moist coke screening in fixed plant installations. It is not suitable as a replacement for rotary breakers or for handling highly sticky materials without pretreatment. Maximum lump size should not exceed 150% of the nominal top deck aperture.
3. بنيادي خاصيتون
ماڊلر ڊيڪ سسٽم | ٽيڪنيڪل بنياد: گوليون, pretensioned panel design with polyurethane side tensioning strips | آپريشنل فائدا: Individual deck sections can be replaced in under 2 hours without welding or specialized tools, minimizing downtime for maintenance. | ROI اثر: Reduces screen cloth changeout time by up to 60%, سڌو سنئون پلانٽ جي دستيابي کي وڌائڻ.
DualMass ڊرائيو ٽيڪنالاجي | ٽيڪنيڪل بنياد: Two synchronized counterrotating masses generating a linear stroke | آپريشنل فائدا: Transfers dynamic forces into the screening motion rather than the support structure; allows for lower horsepower motors due to efficient energy transfer. | ROI اثر: Cuts structural maintenance costs by an estimated 40% and reduces operational energy consumption by 1525%.
Abrasion Resistant استر پيڪيج | ٽيڪنيڪل بنياد: Bolton wear plates made from AR400 steel at all critical impact points (کاڌو خانو, نڪ نڪرندڙ لب) | آپريشنل فائدا: Protects the main screen frame from wear, extending its service life beyond 10 years under typical conditions. | ROI اثر: Eliminates need for frequent frame repair or replacement, providing a predictable longterm asset cost.
Environmental Sealing System | ٽيڪنيڪل بنياد: Multistage labyrinth seals combined with durable rubber dust curtains at transfer points | آپريشنل فائدا: Contains dust emissions at source, improving site environmental compliance and operator health conditions. | ROI اثر: Lowers costs associated with airborne particulate control and reduces housekeeping labor.
Tuned Spring Isolation | ٽيڪنيڪل بنياد: Computermodeled coil spring or rubber shear mount system matched to screen weight and operating frequency | آپريشنل فائدا: تائين الڳ ڪري ٿو 95% of dynamic vibration from the supporting structure, preventing damage to building foundations and adjacent equipment. | ROI اثر: Eliminates secondary structural costs and prevents costly vibrationinduced failures in plant infrastructure.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | ڪوڪ وائبريشن اسڪرين حل | فائدو (% سڌارو) |
| : | : | : | : |
| Deck Panel Replacement Time| 68 ڪلاڪ (welded) | <2 ڪلاڪ (bolted modular) | ~70% تيز |
| ساخت جي ٿڪل زندگي| 35 years before major repair| 8+ years with protected frame| >100% واڌارو |
| اسڪريننگ جي ڪارڪردگي (Breeze Removal)| ~85% efficiency| مسلسل >92% ڪارڪردگي| ~8% more product recovery |
| Operating Noise Level| 95105 ڊي بي(اي) ۽ 1 م| <85 ڊي بي(اي) ۽ 1 م| ~15 dB reduction |
| Annual Power Consumption| بيس لائين (100%) for same duty| Reduced motor size + موثر ڊرائيو| 1525% گهٽتائي |
5. ٽيڪنيڪل وضاحتون
ظرفيت جي درجه بندي: ماڊل تي منحصر; معياري حد کان 300 MTPH کان 1,200 MTPH of bulk coke (bulk density ~0.5 t/m³).
بجلي جي گهرج: Driven by dual lowvoltage AC motors (مثال, 2 x 11 kW کان 2 x 30 ڪلواٽ), depending on model size and stroke configuration.
مواد جي وضاحت:
فريم: Heavyduty ڪاربان اسٽيل (ايس 355 جي آر), دٻاءُ گهٽ.
ڊيڪ: Options include highcarbon steel wire mesh (65من), HARDOX® punch plates, or polyurethane panels.
Wear Protection: AR400 steel liners standard at all impact zones.
جسماني طول و عرض: Typical singledeck unit footprint ranges from (ايل)6m x (ڊبليو)2.5m x (ايڇ)1.8m to (ايل)9m x (ڊبليو)3.5m x (ايڇ)2م.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 50 ° C تائين محيطي درجه حرارت لاء ٺهيل; capable of handling hot coke up to ~200°C with appropriate deck material selection.
6. درخواست جا منظر
Integrated Steel Plant Coke Oven Battery Discharge
چيلنج: A major steel producer faced severe blinding on their existing screens due to residual moisture in quenched coke. This caused frequent overloads on downstream crushers and inconsistent blast furnace feed sizing (+/15mm تفاوت).
حل: Implementation of two parallel heavyduty linear motion Coke Vibration Screens featuring nonblinding balltray decks on the fines removal section.
نتيجا: Screening efficiency stabilized at ≥94%. Oversize contamination was eliminated (<1%), protecting crusher integrity. The consistent product sizing contributed to a documented ~3% improvement in blast furnace burden permeability.
Merchant Coke Producer – Breeze Recovery
چيلنج: A merchant plant was losing significant revenue due to poor fines capture; an estimated 810% of saleable breeze was being incorrectly routed back into crusher feed circuits as "circulating load."
حل: Retrofitting a dedicated Coke Vibration Screen with a finemesh secondary deck into their product classification circuit postcrushing.
نتيجا: Breeze recovery increased from ~82% to over 95%, creating an additional revenue stream exceeding project payback within one year based on market prices for fuelgrade fines.
7.تجارتي خيالات
اسان جون ڪوڪ وائبريشن اسڪرينون پيش ڪيون ويون آھن ٽن پرائمري سطحن تي:
معياري ڊيوٽي سيريز: For capacities up to ~500 MTPH with robust base specifications; ideal for smaller plants or less severe duty cycles.
HeavyDuty سيريز (>500 MTPH): Our most common specification featuring all core technologies listed above; designed for continuous operation in integrated steel plants.
ڪسٽم انجنيئر حل: For unique layouts requiring multiple discharge points specific grades like nut coke separation
اختياري خاصيتون شامل آهن:
Enclosed designs with integrated dust extraction flanges
Stainless steel components for highly corrosive environments
ترقي يافته حالت مانيٽرنگ سينسر
متغير فریکوئنسي ڊرائيو
Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including guaranteed spare parts availability Financing options including leasing are available through our partners
FAQ
What is your typical lead time?
For standard HeavyDuty Series models lead time is typically between weeks depending on current production schedules Custom engineered solutions require additional engineering time
Are your screens compatible with our existing chutes?
Our engineering team will review your existing layout drawings We provide detailed interface specifications including loads connection points ensuring seamless integration into your current transfer system
How do you guarantee performance?
Performance guarantees are based on agreedupon feed material characteristics We provide certified capacity curves based on laboratory testing data Guarantees typically cover throughput capacity under specified conditions
What does commissioning involve?
Our standard package includes supervision installation mechanical alignment initial startup process tuning We ensure correct operation before handover Documentation includes detailed manuals training materials
What are payment terms?
Standard commercial terms involve progress payments tied key milestones Typically % upon order % before shipment balance upon completion satisfactory commissioning Letters credit accepted Financing options available upon request
