Coke Vibration Screen Companies Quote
1. HAPJE NGA PIKA E DIKIMIT
A po lufton operacioni juaj i trajtimit të koksit me pengesa të vazhdueshme?, gjenerimi i gjobave të tepërta, dhe kostot e paplanifikuara të mirëmbajtjes? Ekzaminimi joefikas ndikon drejtpërdrejt në linjën tuaj përfundimtare përmes produktit të humbur, rritja e konsumit të energjisë për proceset në rrjedhën e poshtme, dhe kohë joproduktive të kushtueshme për zëvendësimet e kuvertës së ekranit. Aktualisht po përballeni:
Bartja e gjobave të larta: Ineffective separation leading to valuable coke breeze contaminating the product stream, reducing overall yield and saleable tonnage.
Frequent Screen Blinding & Koha e ndërprerjes: Moisture and sticky fines clogging screen apertures, requiring frequent shutdowns for manual cleaning or deck replacement, duke ndaluar të gjithë linjën tuaj të përpunimit.
Veshja e tepërt e pajisjeve: Uncontrolled vibration and impact from oversized material or poor feed distribution accelerating wear on screen panels, strukturat mbështetëse, and springs.
Klasifikimi i paqëndrueshëm i produktit: Fluctuating feed rates or improper screening action resulting in offspec product that fails to meet stringent customer or internal blast furnace specifications.
Kostot e larta operacionale: The cumulative effect of these issues—lost production, high maintenance labor costs, and premature component failure—erodes plant profitability.
The solution lies in specifying a vibration screen engineered explicitly for the abrasive, highimpact demands of coke classification. The right equipment transforms these operational challenges into controlled efficiency.
2. PËRMBLEDHJE E PRODUKTIT
A Coke Vibration Screen is a heavyduty industrial screening machine designed for the precise size separation of metallurgical coke and coke breeze. Its primary function is to ensure a clean, onspec product while maximizing throughput and minimizing fines loss.
Rrjedha e punës operative:
1. Furnizimi i kontrolluar: Sized coke from the crusher or cooler is delivered onto the screen via a regulated feed box to ensure even distribution across the full width of the screening surface.
2. HighIntensity Separation: A robust vibrator assembly (exciters or unbalanced motors) imparts a linear or elliptical motion to the screen box. This action stratifies the material, forcing undersize particles (fllad koks) through the defined screen panel apertures.
3. Positive Material Discharge: Materiali i tepërt (produkt koks) travels along the deck length and discharges at the end of the screen, while undersize material is collected in a hopper beneath the decks for separate conveyance.
Fusha e Aplikimit & Kufizimet:
This equipment is specifically designed for hot or cold coke sizing in coke handling plants, sistemet e karikimit të furrës së shpërthimit, and anode production facilities. It is not suitable for wet screening applications without significant modification or for processing materials with drastically different bulk densities and abrasiveness without a full engineering review.
3. TIPARET THEMELORE
Sistemi i Mbështetjes së Kuvertës HeavyDuty | Baza Teknike: Reinforced crossmembers with bolted, modular panel attachment | Përfitimi Operacional: Eliminates panel flexing and fatigue failure under heavy load; allows for rapid, individual panel replacement without welding | Ndikimi i ROI: Redukton kohën e ndërprerjes së kuvertës deri në 60% krahasuar me sistemet e salduara.
Teknologjia e kuvertës kundër verbërimit | Baza Teknike: Polyurethane or rubberclad screen panels with flexible, selfcleaning apertures | Përfitimi Operacional: Minimizes adhesion of moist fines; panels flex with each vibration cycle to dislodge trapped particles | Ndikimi i ROI: Maintains consistent throughput and grading quality, reducing cleaning shutdown frequency.
DualVibrator Synchronization | Baza Teknike: Two externally mounted exciters synchronized via a gear coupling drive | Përfitimi Operacional: Provides stable, linear vibration force across the entire screen box width; allows for easy adjustment of amplitude | Ndikimi i ROI: Ensures uniform screening efficiency and extends bearing life through balanced load distribution.
SubResonant Spring Isolation | Baza Teknike: Screen box mounted on highcycle composite rubber springs or steel coil springs tuned below resonance frequency | Përfitimi Operacional: Izolohet deri në 95% të forcave dinamike nga struktura mbajtëse; allows installation on elevated platforms without major structural reinforcement | Ndikimi i ROI: Lowers installation costs and prevents vibration damage to surrounding infrastructure.
Paketa e rreshtimit Rezistent ndaj Abrasionit | Baza Teknike: Wear plates lined with AR400 steel at all critical impact points (kutia e ushqimit, buzët e shkarkimit) | Përfitimi Operacional: Protects the main screen body from direct abrasion by coarse coke | Ndikimi i ROI: Extends structural life of the main asset by years, deferring major capital expenditure.
Enclosed Dust Sealing System| Baza Teknike: Continuous rubber sealing strips between decks and around access doors| Përfitimi Operacional: Contains dust emissions at transfer points for a cleaner, safer working environment| Ndikimi i ROI: Reduces housekeeping labor and aids in compliance with plant environmental standards.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi i Industrisë | Zgjidhja e ekranit me dridhje të koksit | Avantazhi (% përmirësim) |
| : | : | : | : |
| Jeta e shërbimit të panelit të kuvertës | 36 muaj (çeliku standard) | 918 muaj (modular polyurethane/AR combo) | +100% te +200% |
| Efikasiteti i shqyrtimit (for target size)| ~8590% | Konsistente 9396% efficiency maintained over time due to antiblinding tech| +5% fitim absolut |
| Annual Downtime for Screen Maintenance| 80120 orë/vit (pastrimi & changes) | 3050 orë/vit (modular changes only)| ~60% ulje |
| Vibration Transmission to Structure| Të rëndësishme; often requires stiffening| Minimale (90% isolation |
| Amplitude Adjustment Process| Requires adding/removing eccentric weights; downtime needed| External adjustment via variable counterweights or motor speed control; operational adjustment possible.| Time savings >75% per adjustment |
5. SPECIFIKIMET TEKNIKE
Kapaciteti & Vlerësimi: Projektuar për xhiro nga 50 TPH te 1,200+ TPH depending on model size and aperture selection.
Kërkesat për fuqi: Drejtuar nga motorë me vibrator të dyfishtë duke filluar nga 2 x 7.5 kW në 2 x 45 kW (400/690V, 50/60Hz). Drive motor requirements vary by model.
Specifikimet e materialit: Main frame Carbon steel (ST37). Wear surfaces Replaceable AR400 steel liners. Screen panels Modular polyurethane rubber tensioned panels OR perforated steel plate panels with abrasionresistant treatment.
Dimensionet fizike: Beqare, dyfishtë, ose konfigurimet e trefishtë të disponueshme. Typical widths from 1.2m to 3.6m; lengths from 4m to 10m inclusive of feed/discharge boxes.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 20°C deri në +50°C. Handles material temperatures up to ~150°C continuously with appropriate component specifications.
6. Skenarët e APLIKIMIT
Blast Furnace Coke Screening Plant
Challenge A major integrated steel mill experienced excessive fines (<10mm) in their blast furnace feed stock due to degraded screenscreen decks blinding daily through moisture ingress causing inconsistent sizing that risked furnace permeability
Solution Installation of two tripledeck Coke Vibration Screens featuring selfcleaning polyurethane panels on top/middle decks combined with high open area wire mesh bottom decks
Results Achieved consistent product grading with <2% fines carryover eliminated two daily manual cleaning shifts reduced annual maintenance hours by over four hundred
Coke Breeze Recovery Circuit
Challenge An independent coke producer was losing significant revenue as valuable breeze was being misdirected into waste streams due an inefficient singledeck vibrating screen
Solution Implementation of a dedicated doubledeck fine Coke Vibration Screen equipped with specialized ball tray decks prevent blinding on fine mesh apertures
Results Recovered an additional metric tons per hour saleable breeze increasing annual revenue by over fifteen percent achieving full payback within eight months
Anode Grade Coke Sizing
Challenge A carbon plant required extremely tight particle size distribution control but their existing screens produced excessive attrition generating unwanted ultrafines during classification process
Solution Commissioning customengineered lowattrition linear motion Coke Vibration Screens featuring gentle material handling low stroke/highfrequency design combined cascading deck arrangement
Results Reduced generation minus fraction by thirty percent while meeting stringent topsize cut point specification improving downstream paste mixing consistency
KONSIDERATA TREGTARE
Pricing tiers are primarily determined by machine size deck count features:
Base Model Tier Standard duty construction fixed amplitude vibrators conventional steel panels suitable lower capacity replacement applications
Performance Tier Includes antiblinding decks adjustable amplitude vibrators composite spring isolation extended wear linings recommended new installations major upgrades
Premium Tier Full custom engineering including special materials dust suppression hoods advanced monitoring sensors predictive maintenance integration
Optional Features Include spray systems dust encapsulation covers variable frequency drives remote monitoring kits different panel types access platforms walkways
Service Packages Available as factory commissioning multiyear parts kits annual inspection contracts full maintenance agreements ensuring operational readiness
Financing Options Flexible acquisition models include outright purchase capital lease operating lease structures tailored support project financing large capital projects
FAQ
What is typical lead time delivery new Coke Vibration Screen?
Lead times vary based complexity customization standard designs typically available within weeks fully customized units may require months detailed engineering fabrication commence upon order approval
Can this equipment integrate existing conveyor feed system?
Yes screens are engineered accept standard belt conveyor feeds require properly designed feed box ensure even distribution across full width maximize efficiency prevent localized wear
How does power consumption compare older screening equipment?
Modern designs focus energy efficiency direct drive exciters premium efficiency motors typically result similar marginally lower consumption compared older units while delivering significantly higher throughput reliability
What key factors determining correct screen size my application?
Primary factors are total required tonnage per hour desired separation sizes percentage open area selected panels material bulk characteristics consultation application engineer essential specify correctly
Janë pjesë këmbimi në dispozicion?
Manufacturers maintain comprehensive inventory critical wear parts vibrator assemblies springs panel modules ensuring availability minimize potential extended downtime events
