Coke Vibration Screen ODM Manufacturer
1. PAINPOINT driven اوپننگ
Is your coke handling operation plagued by persistent bottlenecks, وڌيڪ سار سنڀال جي خرچ, and inconsistent product quality? ڪوڪ اسڪريننگ جي نگراني ڪندڙ پلانٽ مينيجرز لاءِ, common challenges directly impact the bottom line:
انڌو ڪرڻ & بند وقت: ٺيڪ, نم ڪوڪ ذرڙا اسڪرين ڊيڪ تي لڳل آهن, تيز انڌو ٿيڻ جو سبب. This reduces effective screening area by up to 40%, forcing frequent shutdowns for manual cleaning and slashing throughput.
وقت کان اڳ جو لباس & High OPEX: The abrasive nature of metallurgical coke accelerates wear on screen panels, ڊيڪ, ۽ exciters. Unplanned component replacements and associated labor can increase annual maintenance budgets by 25% يا وڌيڪ.
غير موثر جزا جدا ڪرڻ: 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.
ساخت جي ٿڪ & 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. پيداوار جو جائزو
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 (مثال, ڌماڪي جي فرنس ڪوڪ, نٽ ڪوڪ, هوا) while efficiently removing fines.
آپريشنل ڪم فلو:
1. کاڌو & ورهائڻ: Crushed coke is uniformly fed onto the inlet end of the inclined screen deck via a chute or feeder.
2. Stratification & جدائي: تيز شدت, linear or elliptical vibration stratifies the material bed. Smaller particles pass through precisely sized deck apertures; oversized particles travel across the deck surface.
3. خارج ٿيڻ: 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.
ايپليڪيشن جو دائرو: Primary sizing of metallurgical coke after crushing; scalping of oven discharge; dedusting and fines removal; recovery operations.
حدون: خاص ڊيڪ ٽيڪنالاجي کان سواء چپچپا مواد لاء ٺهيل ناهي; maximum feed size is constrained by deck opening and machine design; requires controlled feed rate for optimal efficiency.
3. بنيادي خاصيتون
HeavyDuty Deck System | ٽيڪنيڪل بنياد: Modular polyurethane or rubberclad steel panels with reinforced fixing | آپريشنل فائدا: Dramatically increased service life under abrasive conditions; reduced noise levels (by ~10 dBA); panels are easily replaced in sections minimizing downtime | ROI اثر: Cuts panel replacement costs by up to 60% over traditional woven wire decks.
AntiBlinding Technology | ٽيڪنيڪل بنياد: Integrated ball tray decks or ultrasonic screen mesh cleaning systems | آپريشنل فائدا: Continuous microimpact dislodges lodged particles near aperture openings maintaining nearoriginal open area | ROI اثر: Sustains design capacity throughput reduces cleaning downtime by over 70%.
Balanced Elliptical Vibration | ٽيڪنيڪل بنياد: Twin shaft exciter with outofphase synchronized weights generating an elliptical throw pattern | آپريشنل فائدا: Optimized material travel speed with sharp stratification enhances separation accuracy especially for midrange sizes (1030ايم ايم) | ROI اثر: Improves product purity by an average of 15% reducing recrush load and maximizing premium fraction yield.
بند ٿيل ڊسٽ ٽائيٽ ڊيزائن | ٽيڪنيڪل بنياد: Gasketed side plates and dust hood connections with integral skirt boards | آپريشنل فائدا: Contains airborne coke dust at transfer points improving site air quality meeting environmental standards | ROI اثر: Lowers housekeeping costs mitigates health safety risks avoids potential regulatory noncompliance fines.
الڳ ٿيل وائبريشن فريم | ٽيڪنيڪل بنياد: Dynamic vibration isolators (rubber or spring) between the vibrating body and stationary base frame | آپريشنل فائدا: وڌيڪ جذب ڪري ٿو 95% of dynamic forces preventing transmission to supporting structures eliminates fatigue failures | ROI اثر: Removes need for massive dedicated foundations reduces installation time capital cost protects plant infrastructure integrity.
Centralized Greasing Lube System | ٽيڪنيڪل بنياد: Manifold with lines feeding all major bearing points from a single access port | آپريشنل فائدا: Enables safe rapid lubrication during brief pauses extends bearing life under highload hightemperature conditions | ROI اثر: Standardizes preventive maintenance intervals reduces bearing failure rates by an estimated 40%.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | ڪوڪ وائبريشن اسڪرين حل | فائدو (% سڌارو) |
|||||
| Deck Panel Lifespan | Woven wire mesh lasts 23 مهينو سخت ڇڪڻ هيٺ | Polyurethaneclad modular panels last 812 مهينا | +300% خدمت زندگي |
| اسڪريننگ جي ڪارڪردگي | ~85% efficiency for midsize separation due to blinding | برقرار رکي ٿو >92% efficiency via antiblinding systems | +78% مسلسل ڪارڪردگي |
| سار سنڀال بند وقت | 812 hours monthly for cleaning bearing checks panel replacement
| Energy Consumption per Ton ~0.12 kWh/ton processed
| Breeze (10ايم ايم) Contamination in Product Fraction
5. ٽيڪنيڪل وضاحتون
ظرف / درجه بندي: ماڊل تي منحصر 200 TPH کان مٿي 1500 TPH throughput capacity standard designs available
بجلي جي گهرج: Drive motor range from 7.5 kW کان 45 kW depending on screen size mass excitation force
مواد جي وضاحت: Highstress frame components S355JR steel side plates wear liners Hardox®400 Abrasionresistant polyurethane rubber composite deck materials
جسماني طول و عرض (عام ماڊل): Deck Size (LxW): 3m x1 .5m Overall length:~4 .2m Overall width:~2 .8m Height:~1 .6m Weight:~6500kg
ماحولياتي آپريٽنگ رينج: ماحول جي درجه حرارت:20°C +50°C Feed material temperature upto120°C(وڌ ۾ وڌ) Weather protection IP65 enclosure optional
6. درخواست جا منظر
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
حل:: Installation two large doubledeck Coke Vibration Screens equipped ball tray antiblinding decks isolated base frames
نتيجا:: 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<25ايم ايم)from single feed stream but existing separator generated excessive fines(<10ايم ايم)in midrange fraction reducing its market value
حل:: Implementation multislope Coke Vibration Screen with precision elliptical vibration finetuning deck tensioning system
نتيجا:: Product purity each fraction achieved>95%. Revenue from midrange(2550ايم ايم)fraction increasedby18%due reduced fines content System handled variable feed rates without performance degradation
7. تجارتي خيالات
سامان جي قيمت جا درجا: Entrylevel standard duty screens(starting~$25000);Heavyduty customengineered units($65000$200000+)based size configuration options
اختياري خاصيتون / واڌارو: 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
سروس پيڪيجز: 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. FAQ
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
