Coke Vibration Screen Manufacturing Design Service
1. PAINPOINT driven اوپننگ
ڇا توهان جو ڪوڪ هينڊلنگ آپريشن مسلسل رڪاوٽن ۽ وڌندڙ سار سنڀال جي خرچن کان متاثر آهي? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, غير موثر اسڪريننگ سڌي طرح هيٺئين لائن تي اثر انداز ٿئي ٿي. عام چئلينج شامل آهن:
انڌو ڪرڻ & کڻندڙ: ٺيڪ, 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.
ضرورت کان وڌيڪ بند وقت & سار سنڀال: Traditional screens with complex drive mechanisms and numerous moving parts require frequent lubrication, belt changes, and bearing replacements, غير منصوبابندي بند ڪرڻ جي ڪري.
اعلي توانائي واپرائڻ: Inefficient vibratory systems operate at constant high power, regardless of feed conditions, wasting significant energy over thousands of operational hours.
Structural Fatigue & 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. پيداوار جو جائزو
Our engineered service provides heavyduty Coke Vibration Screens, specifically designed for the abrasive and demanding environment of coke handling in steel production, anode نباتات, and calcining operations.
آپريشنل ڪم فلو:
1. کاڌو & ورهائڻ: 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: هڪ طاقتور, linear vibratory motion stratifies the material bed, forcing fines downward through the screen media while conveying oversize toward the discharge end.
3. قطعي جدائي: Multiple deck configurations allow for precise separation into two or three distinct product streams (مثال, nut coke from breeze).
4. ڪنٽرول ٿيل خارج ٿيڻ: Separated fractions are discharged via dedicated chutes for downstream processing or stockpiling.
ايپليڪيشن جو دائرو: Primary and secondary screening of metallurgical (met) ڪوڪ, petroleum coke (پيٽ ڪوڪ), and calcined coke in sizing ranges typically from 080mm.
حدون: Not designed for extremely fine classification (<1ايم ايم) which requires specialized fine screening technology, or for materials at temperatures exceeding 250°C without specific design adaptations.
3. بنيادي خاصيتون
ماڊلر ڊيڪ سسٽم | ٽيڪنيڪل بنياد: Independently tensioned polyurethane or wire cloth panels on a rigid subframe | آپريشنل فائدا: Panels can be replaced individually without dismantling adjacent decks or extensive downtime. Damaged sections are isolated for quick changeout. | ROI اثر: Reduces deck replacement labor time by up to 60%, minimizing production interruptions.
DualMass Vibrator Drive | ٽيڪنيڪل بنياد: Two counterrotating eccentric masses generating a linear force along a defined stroke line | آپريشنل فائدا: Transmits dynamic forces internally within the vibrator assembly rather than to the screen body and support structure. Starts smoothly under full load. | ROI اثر: Cuts structural maintenance costs by up to 40% and extends overall screen frame life by years.
Huck Bolt® Frame Construction | ٽيڪنيڪل بنياد: Highstrength aircraftstyle fasteners providing consistent clamp force across joints | آپريشنل فائدا: Eliminates weld fatigue failures at critical stress points on side plates and cross members under continuous vibratory loading. | ROI اثر: Dramatically reduces risk of catastrophic frame failure, ensuring multiyear structural integrity with minimal intervention.
متغير فريڪوئنسي ڊرائيو (وي ايف ڊي) Compatibility | ٽيڪنيڪل بنياد: Integration with VFD controls to adjust motor speed (آر پي ايم) | آپريشنل فائدا: Operators can finetune vibration amplitude and material travel speed in response to changes in feed rate or moisture content to optimize efficiency. | ROI اثر: Enables energy savings during lower throughput periods and optimizes performance without mechanical adjustments.
DustEncapsulated Bearing Assembly | ٽيڪنيڪل بنياد: Labyrinth seals combined with positivepressure purge systems on vibrator shaft bearings | آپريشنل فائدا: Effectively excludes abrasive coke dust from critical bearing housings in a highparticulate environment. | ROI اثر: Extends bearing service life by 23x compared to standard seals, preventing a primary cause of drive failure.
AbrasionResistant Lining Packages | ٽيڪنيڪل بنياد: Bolton wear liners made from AR400 steel or specialized ceramics at highimpact points (کاڌو خانو, نڪ نڪرندڙ لب) | آپريشنل فائدا: Protects structural steel from direct abrasion, preserving base metal integrity. Liners are sacrificial components designed for easy replacement. | ROI اثر: Turns major plate repair projects into simple liner swaps, saving on both material costs and extended welding downtime.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | Industry Standard Coke Screen Design | اسان جو ڪوڪ وائبريشن اسڪرين حل | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي / اپٽائم| ~9294%, factoring in monthly maintenance stops for lubrication & adjustments.| >96%, achieved through sealedforlife vibrators & reduced lubrication points.| +34% increased production time |
| Deck Panel Change Time| 812 hours for full deck access & retensioning.| <4 hours via modular panel design & external tensioning system.| تائين 60% تيز |
| توانائي واپرائڻ في ٽين| Fixed power draw regardless of load; اندازي مطابق 0.15 kWh/ton.| VFDoptimized operation reduces draw under partial load; سراسري. 0.11 kWh/ton.| ~27% reduction possible |
| بيئرنگ زندگي جي توقع| 1218 months in dusty conditions with standard seals.| 36+ months with multistage dust encapsulation systems.| +100% سڌارو |
| ساخت جي ٿڪل زندگي| Major weld inspections/rework every 35 years due to stress cracking.| Huckbolted construction targets >10year frame life without major weld repair.| +100% سڌارو |
5. ٽيڪنيڪل وضاحتون
ظرف / درجه بندي: Sizing capacities from 200 TPH کان مٿي 2,500 TPH depending on model aperture size.
بجلي جي گهرج: Drive motors ranging from 15 kW کان 75 kW في وائيبريٽر يونٽ (عام طور تي dualdrive), compatible with 400/690VAC, 50/60Hz supply.
مواد جي وضاحت:
فريم & پاسي واري پليٽ: Highyield strength carbon steel (Q345B / A572 Grade 50 equivalent).
Deck Support Beams: Reinforced hollow section beams.
اسڪرين ميڊيا جا اختيار: Tensioned polyurethane پينل (ڊگھي عمر لاء), woven wire cloth (for sharpness of cut), punch plate (for heavyduty scalping).
جسماني طول و عرض: ويڪر 1.2m کان 3.6m تائين; lengths from 4.8m to over 10m for multideck configurations.
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; material temperature up to ~150°C standard (higher temp options available). Weather covers and dust enclosures are optional.
6. درخواست جا منظر
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 .
پيٽروليم ڪوڪ ڪليننگ پلانٽ
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
تجارتي خيالات
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
FAQ
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
