White Label Coke Vibration Screen Brochure
White Label Coke Vibration Screen Brochure
The Cost of Inefficient Coke Screening: Are You Losing Margin on Every Ton?
Coke producers and processors face persistent operational challenges that directly impact profitability. Fugitive dust emissions from traditional screening equipment can exceed 50 mg/Nm³, triggering regulatory penalties and increasing maintenance frequency. انڌو ڪرڻ ۽ پگهرائڻ of screen media in sticky coke applications causes throughput reductions of 1525%, forcing unscheduled downtime every 7296 ڪلاڪ. Screen deck wear from abrasive coke particles accelerates replacement cycles to 68 هفتا, with each changeover costing $4,000$8,000 گم ٿيل پيداوار ۽ محنت ۾. نامناسب ذرات جي ماپ جي ورڇ—particularly the critical +25mm and 6mm fractions—leads to rejected shipments and customer penalties averaging $1218 في ٽون. High noise levels (95105 ڊي بي) from conventional screens create OSHA compliance risks and operator fatigue.
Can your current screening solution maintain consistent cutpoint accuracy at 200 TPH while controlling dust below 10 mg/Nm³? Are you replacing screen panels every 45 days when a properly engineered solution could extend that interval to 16 هفتا? This brochure presents a white label vibration screen engineered specifically for coke applications, designed to address these exact operational pain points.
پيداوار جو جائزو: HeavyDuty Linear Motion Vibration Screen for Coke Processing
This white label vibration screen is a dualshaft, linear motion vibratory classifier purposebuilt for dry or wet screening of metallurgical coke, پيٽروليم ڪوڪ, ۽ calcined ڪوڪ. The equipment operates on a forcedsynchronization principle using two counterrotating vibrator motors mounted at 45° to the screen deck, producing a straightline throw that conveys material across the screening surface while stratifying particles by size.
آپريشنل ڪم فلو:
1. فيڊ جي تقسيم: Coke material (080ايم ايم) enters via a flanged inlet chute, distributed evenly across the full deck width by a feed box with replaceable wear liners (AR400 or ceramic tile).
2. Stratification & پهچائڻ: لڪير واري حرڪت (68mm طول و عرض تي 8501000 آر پي ايم) lifts and tumbles the material bed, allowing fines to contact the screen surface while oversize travels toward the discharge end.
3. ماپ الڳ ڪرڻ: Material passes through woven wire, polyurethane, or perforated plate media (custom aperture from 3mm to 50mm). Undersize falls to a collection hopper; oversize exits via a discharge spout.
4. مٽي ڪنٽرول: A bolted, gasketed enclosure with negative pressure ports captures airborne particulates, routing them to a baghouse or wet scrubber.
5. خارج ٿيڻ & ٻيهر دعويٰ ڪرڻ: Two or three product streams (ڏنڊ, وچولي, وڏو ڪرڻ) are directed to downstream conveyors or storage bins.
ايپليڪيشن جو دائرو: Primary and secondary screening of blast furnace coke, ڪوڪ ملائڻ, anodegrade پيٽروليم ڪوڪ, and calcined coke for aluminum smelting. Suitable for dry screening at 36% moisture or wet screening with spray bars (پاڻي واپرائڻ: 0.51.5 m³/ٽن).
حدون: Not recommended for materials exceeding 80°C surface temperature without hightemperature bearing upgrades. Maximum feed moisture for dry screening: 8% (above this, blinding becomes significant). Throughput capacity decreases by 3040% when screening below 3mm aperture.
بنيادي خاصيتون
HeavyDuty Vibrator اسيمبلي | ٽيڪنيڪل بنياد: Dualshaft, oillubricated exciter with spherical roller bearings | آپريشنل فائدا: Generates consistent linear motion (610mm stroke) without belt slippage or phase shift, maintaining cutpoint accuracy within ±2% of aperture size | ROI اثر: Reduces rescreening costs by $0.500.80 في ٽون; extends bearing life to 25,000+ ڪم جا ڪلاڪ
Modular Screen Deck System | ٽيڪنيڪل بنياد: Tensioned, boltdown polyurethane or modular polydeck panels with 4060% کليل علائقو | آپريشنل فائدا: Panel replacement in 23 ڪلاڪ جي مقابلي ۾ 812 hours for traditional wedgewire decks; no welding required | ROI اثر: Reduces annual maintenance labor by 120180 ڪلاڪ; panel life of 1418 weeks in coke service
Integrated Dust Containment Enclosure | ٽيڪنيڪل بنياد: Welded steel housing with continuous gasket seals and negative pressure plenum (0.51.0 ۾. H₂O) | آپريشنل فائدا: قبضو ڪري ٿو 99.5% of fugitive dust at source; eliminates need for external hoods or shrouds | ROI اثر: Avoids EPA fines of $15,00050,000 خلاف ورزي تي; reduces baghouse filter replacement frequency by 40%
متغير فريڪوئنسي ڊرائيو (وي ايف ڊي) ڪنٽرول | ٽيڪنيڪل بنياد: 3phase AC motor (1550 ايڇ پي) controlled by VFD, adjusting RPM from 6001200 | آپريشنل فائدا: Operators can finetune stroke frequency for varying coke moisture (38%) ۽ فيڊ جي شرح (150300 ٽي پي ايڇ) | ROI اثر: توانائي جي بچت 1218% versus fixedspeed operation; reduces screen blinding by 35% گندي حالتن ۾
Replaceable Wear Liner Package | ٽيڪنيڪل بنياد: AR400 steel or 92% alumina ceramic tiles in feed box, discharge spouts, and sidewall impact zones | آپريشنل فائدا: Wear life of 812 months in highimpact areas versus 34 months for standard mild steel | ROI اثر: Reduces replacement part costs by $6,00012,000 سالانه; ختم ڪري ٿو 23 هر سال غير شيڊول بند
QuickRelease Tensioning System | ٽيڪنيڪل بنياد: Pneumatic or hydraulic tensioning rails with camlock mechanisms for screen media | آپريشنل فائدا: Screen media changeover in 45 منٽ جي مقابلي ۾ 34 hours with manual bolt systems | ROI اثر: Increases equipment availability by 23%; reduces changeover labor costs by $400600 في واقعي
Integrated Spray Bar Option (Wet Screening) | ٽيڪنيڪل بنياد: Stainless steel spray bars with adjustable nozzles (3060 psi) positioned at 15° angle to deck | آپريشنل فائدا: Removes adhering fines from coke surfaces; مٽي جي پيداوار کي گھٽائي ٿو 90% during wet operation | ROI اثر: Improves product quality by reducing ash carryover; lowers water consumption to 0.8 m³/ton versus 1.5 m³/ton for conventional systems
مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (Conventional Inclined Screen) | White Label Coke Vibration Screen | فائدو (% سڌارو) |
| : | : | : | : |
| اسڪريننگ جي ڪارڪردگي (% passing target aperture) | 8590% | 9497% | 810% سڌارو |
| اسڪرين ميڊيا لائف (هفتا, coke service) | 68 هفتا | 1418 هفتا | 100125% گهڻي زندگي |
| مٽي جو اخراج (mg/Nm³) | 3555 mg/Nm³ | 512 mg/Nm³ | 7585% گهٽتائي |
| اڻ شيڊول بند وقت (ڪلاڪ/مهينو) | 814 ڪلاڪ | 24 ڪلاڪ | 6575% گهٽتائي |
| توانائي جو واھپو (kWh/ٽن) | 0.450.65 kWh/ٽن | 0.320.48 kWh/ٽن | 2028% گھٽ واپرائڻ |
| شور جي سطح (ڊي بي تي 1 ميٽر) | 95105 ڊي بي | 8288 ڊي بي | 1015 ڊي بي جي گھٽتائي |
| تبديليءَ جو وقت (اسڪرين ميڊيا) | 34 ڪلاڪ | 45 منٽ | 7580% تيز |
| CutPoint Accuracy (±% of aperture) | ±5% | ±2% | 60% سخت رواداري |
ٽيڪنيڪل وضاحتون
| پيرا ميٽر | تفصيل |
| : | : |
| ماڊل رينج | WLC1224 (4'x8') to WLC2448 (8'x16') |
| ذريعي جي گنجائش | 100350 ٽي پي ايڇ (depending on aperture and feed size) |
| اسڪرين ايريا | 32128 ft² (312 m²) |
| ڊيڪ جو تعداد | 1 يا 2 (حسب ضرورت) |
| اسڪرين ميڊيا جا اختيار | Woven wire (304 ايس ايس), polyurethane (6090 ساحل اي), سوراخ ٿيل پليٽ (AR400) |
| Aperture Range | 3mm to 50mm |
| وائبريشن جو قسم | لڪير واري حرڪت, dualshaft exciter |
| Stroke Amplitude | 610 ايم ايم (سنسڪرت وزن ذريعي ترتيب ڏيڻ) |
| آپريٽنگ فریکوئنسي | 7501050 آر پي ايم (VFD ڪنٽرول) |
| موٽر پاور | 1550 ايڇ پي (1137 ڪلواٽ), 460V/3 مرحلو/60Hz (يا 380V/50Hz) |
| موٽر جو قسم | TEFC, IP55, Class F insulation |
| Deck Angle | 0° (افقي) to 5° (declined) |
| تعميراتي مواد | ڪاربان اسٽيل (A36) يا 304 بي داغ لوه (foodgrade coke) |
| لينر پائڻ | AR400 اسٽيل (معياري), 92% alumina ceramic (اختياري) |
| Dust Enclosure | Bolted steel housing, gasketed, سان 6" يا 8" flanged ports |
| آپريٽنگ جي درجه حرارت جي حد | 20°C to 80°C (معياري); up to 150°C with hightemp bearings |
| وڌ ۾ وڌ فيڊ نمي (خشڪ) | 8% |
| وڌ ۾ وڌ فيڊ سائيز | 80ايم ايم |
| مجموعي طول و عرض (WLC1836) | 18' L x 6' W x 7' H (5.5m x 1.8m x 2.1m) |
| ڪل وزن (WLC1836) | 12,500 lbs (5,670 ڪلو) |
| شور جي سطح | 8288 ڊي بي تي 1 ميٽر (with enclosure) |
ايپليڪيشن منظرنامو
Blast Furnace Coke Screening at Integrated Steel Mill | چيلنج: اي 2.5 MTPA steel plant was experiencing 12% fines carryover (+25mm product contained 8% 6mm مواد), resulting in rejected shipments and $2.1M annual penalties. Existing inclined screens required weekly media replacement due to abrasive wear. | حل: Installed two WLC2448 white label vibration screens with polyurethane modular decks (25mm and 6mm apertures) and integrated dust enclosure. VFD tuning optimized stroke for 5.5% moisture coke at 280 ٽي پي ايڇ. | نتيجا: ڏنڊ کڻڻ تي گھٽجي ويو 1.2% (هيٺ 2% وضاحت). Screen media life extended to 16 هفتا. مٽي جي اخراج جي ماپ تي 8 mg/Nm³. Annual penalty costs eliminated; maintenance labor reduced by 180 ڪلاڪ / سال. ROI ۾ حاصل ڪيو 11 مهينا.
Petroleum Calcined Coke Sizing for Anode Production | چيلنج: An aluminum smelter's calcined coke screening line (150 ٽي پي ايڇ) suffered from 22% blinding of 4mm aperture screens due to residual volatile matter (0.51.0%). This caused throughput to drop to 110 TPH and required daily manual cleaning. | حل: Deployed a WLC1836 white label screen with heated deck option (electrical resistance heating to 60°C) and 4mm polyurethane media. VFD set to 950 RPM with 7mm stroke. Spray bar system added for periodic wet cleaning. | نتيجا: Blinding reduced to 3%. جي ذريعي تي مستحڪم 145 ٽي پي ايڇ. Manual cleaning eliminated. Product size distribution (90% passing 4mm, 95% retained on 0.5mm) met anodegrade specifications. توانائي جو واھپو: 0.38 kWh/ٽن. واپسي جي مدت: 14 مهينا.
Foundry Coke Reclaim from Stockpile | چيلنج: A foundry operation needed to screen 50,000 tons of stockpiled coke (075ايم ايم) to produce 25mm x 50mm foundrygrade product. Existing portable screen plant had 65% efficiency and generated excessive noise (102 ڊي بي) near residential areas. | حل: Provided a mobile WLC1224 white label screen on skid base with dieselhydraulic drive (50 ايڇ پي). Dualdeck configuration: top deck 50mm perforated plate, bottom deck 25mm woven wire. Enclosure with sounddampening panels reduced noise. | نتيجا: اسڪريننگ جي ڪارڪردگي بهتر ٿي وئي 93%. Noise level reduced to 85 ڊي بي تي 50 ميٽر. Production rate: 180 ٽي پي ايڇ. بحال ٿيو 42,000 tons of saleable foundry coke from stockpile. Equipment relocated to three sites over 18 months with zero structural issues.
تجارتي خيالات
سامان جي قيمت جا درجا (FOB Factory, آمريڪي ڊالر):
- معياري پيڪيج (WLC1224): $48,00062,000 (اڪيلو ڇت, ڪاربان اسٽيل, woven wire media, manual tensioning)
- وڌايل پيڪيج (WLC1836): $78,000105,000 (dual deck, polyurethane ميڊيا, وي ايف ڊي, dust enclosure, AR400 لائنر)
- پريميئم پيڪيج (WLC2448): $135,000180,000 (dual deck, سيرامڪ لينر, heated deck option, اسپري بار, pneumatic tensioning, اسٽينلیس سٹیل جي تعمير)
- Hightemperature bearing upgrade (150°C): $4,5007,000
- ريموٽ مانيٽرنگ پيڪيج (vibration sensors, درجه حرارت جي جاچ, PLC interface): $8,50012,000
- Mobile skid or trailer mounting: $12,00018,000
- Integrated dust collection fan and ductwork: $15,00025,000
- Custom screen media (nonstandard apertures, خاص الائي): $2,0005,000 في ڇت
- بنيادي وارنٽي: 12 مهينن جا حصا ۽ محنت (included)
- توسيع وارنٽي: 2436 مهينا, سالياني معائنو ۽ ترجيحي ٽيڪنيڪل سپورٽ شامل آھي: $4,5008,000/سال
- حفاظتي سار سنڀال پروگرام: Quarterly site visits, vibration جو تجزيو, لباس جي ماپ, media replacement planning: $12,00018,000/سال
- آپريٽر ٽريننگ: 2day onsite training for up to 6 اهلڪار: $3,500 (سفر شامل نه آهي)
- نيٽ 30 قابل خريد ڪندڙن لاءِ شرطون (credit check required)
- ليزٽائون: 3660 مهيني جا شرط, monthly payments starting at $1,200 (standard package)
- Equipment financing: 515% هيٺ, 47% اپريل (ڪريڊٽ جي درجه بندي جي بنياد تي)
- مقدار ۾ رعايتون: 5% لاءِ 23 يونٽ, 10% لاءِ 4+ يونٽ
اختياري خاصيتون:
سروس پيڪيجز:
فنانسنگ جا اختيار:
اڪثر پڇيا ويا سوال
ق: Can this white label vibration screen handle coke with moisture content above 8%?
اي: For dry screening, maximum recommended moisture is 8%. Above this, blinding increases significantly. We offer a wet screening option with spray bars (0.51.5 m³/ton water consumption) that handles up to 15% نمي. متبادل طور تي, a heated deck option (electrical resistance to 60°C) can reduce surface moisture effects for materials up to 10% نمي.
ق: What is the typical delivery lead time for a standard unit?
اي: Standard package (WLC1224) ships in 68 آرڊر کان هفتي. Enhanced and premium packages require 1014 weeks due to custom fabrication of dust enclosures and VFD integration. جلدي حڪم (46 هفتا) a تي موجود آهن 15% پريميئم.
ق: How does the white label arrangement work for OEM branding?
اي: We supply the complete screen assembly with your company nameplate, paint color (RAL code), ۽ دستاويز. No manufacturer markings appear on the equipment. Technical drawings and manuals are provided in your brand format. Minimum order: 2 units for custom branding.
ق: What screen media is recommended for metallurgical coke with 57% نمي?
اي: Polyurethane ماڊلر پينل (6070 ساحل A سختي) سان 4050% open area are optimal. They resist blinding from sticky fines and provide 1418 weeks life. For highabrasion applications (مثال, calcined ڪوڪ), 92% alumina ceramic tiles on the feed box and polyurethane on the deck offer the best balance of wear life and cost.
ق: Can the screen be integrated with an existing PLC or SCADA system?
اي: ها. The VFD and vibration monitoring package include Modbus RTU (RS485) or Ethernet/IP communication protocols. We provide a standard tag list and integration guide. For custom PLC programming, شامل ڪريو $2,5004,000 to the premium package.
ق: What is the expected ROI timeline for a typical installation?
اي: کان فيلڊ ڊيٽا جي بنياد تي 47 تنصيب, average payback is 1014 مهينا. Primary savings come from reduced screen media replacement costs (4060% گهٽتائي), lower maintenance labor (120180 ڪلاڪ / سال), improved product quality (eliminating rescreening and penalties), and reduced energy consumption (2028%). A detailed ROI calculator is available upon request.
ق: How does the dust enclosure affect access for maintenance?
اي: The enclosure uses bolted panels with quickrelease latches on inspection doors. All service points (vibrator بيرنگ, screen media tensioning, motor access) are reachable through dedicated access panels. Full enclosure removal for major maintenance takes 23 hours with two technicians. The enclosure is designed to meet OSHA confined space requirements.
