Coke Vibration Screen Contract Manufacturer Customization
1. HAPJE NGA PIKA E DIKIMIT
Is your coke handling operation plagued by persistent inefficiency and unplanned maintenance? For plant managers overseeing coke screening, common challenges directly impact throughput and profitability. Excessive fines contamination in product streams can lead to customer rejections and revenue loss. Frequent screen cloth blinding from sticky, moist coke results in extended downtime for manual cleaning, halting the entire processing line. Premature wear of screen components due to the abrasive nature of coke forces a higherthanbudgeted spend on replacement parts. Vibration isolation failures transmit damaging harmonics to support structures, creating longterm asset integrity concerns. Are you facing rising operational costs, inconsistent product grading, and unreliable equipment availability? The right Ekrani i dridhjeve të koksit is not just a component; it’s a critical determinant of your plant’s continuous performance and bottom line.
2. PËRMBLEDHJE E PRODUKTIT
A Ekrani i dridhjeve të koksit is a heavyduty industrial screening machine designed for the scalping, përmasat, and dedusting of metallurgical coke and petroleum coke (petcoke). Its purpose is to separate material efficiently by particle size after crushing or prior to shipment and blast furnace charging.
Rrjedha e punës operative:
1. Prezantimi i ushqimit: Bulk coke is conveyed onto the feed box of the inclined screen deck.
2. Vibratory Separation: HighGforce linear or elliptical vibration stratifies material, forcing undersize particles through the specified screen cloth apertures.
3. Particle Stratification: Fines pass through first, followed by correctly sized product; nearsize material requiring more time to pass continues down the deck.
4. Shkarkimi: Correctly sized oversize and undersize fractions are discharged from separate outlets onto designated conveyors or bins.
Fusha e Aplikimit & Kufizimet:
This equipment is engineered for highcapacity dry screening of bulk solid coke. Optimal performance assumes controlled feed rates and material with surface moisture typically below 5% to minimize adhesion. It is not suitable as a substitute for a dewatering screen for slurry applications or for materials with significantly higher moisture content without specialized modifications.
3. TIPARET THEMELORE
HeavyDuty Deck Support System | Baza Teknike: Reinforced crossmembers with rubber buffer sleeves | Përfitimi Operacional: Absorbs impact loads from large coke lumps, drastically reducing metal fatigue and structural cracking | Ndikimi i ROI: Extends deck frame service life by up to 60%, reducing structural replacement costs.
AntiBlinding Screen Cloth Technology | Baza Teknike: Polyurethane or rubberclad wire panels with flexible, selfcleaning apertures | Përfitimi Operacional: Panel flex under vibration dislodges lodged particles, maintaining consistent open area and screening efficiency | Ndikimi i ROI: Sustains design capacity, reduces cleaning downtime by up to 80%, and improves product consistency.
DualVibration Motor Drive | Baza Teknike: Two synchronized, externally mounted motors generating linear vibration | Përfitimi Operacional: Simplified maintenance with no complex internal gears; easy adjustment of amplitude; shpërndarja e ekuilibruar e forcës | Ndikimi i ROI: Lower maintenance time and cost versus bruteforce singleshaft drives; improved uptime.
Modular Deck Design | Baza Teknike: Independently tensioned screen panel sections on a unitary frame | Përfitimi Operacional: Allows for quick replacement of worn sections without dismantling the entire deck; enables easy configuration changes (p.sh., different cloth sizes per deck) | Ndikimi i ROI: Reduces cloth changeout labor time by over 50% and minimizes spare parts inventory.
Advanced Isolation System | Baza Teknike: Multilayered rubber shear mounts or air springs | Përfitimi Operacional: Isolates over 95% of dynamic forces from being transmitted to the support structure | Ndikimi i ROI: Eliminates structural damage repairs, reduces ambient noise, and permits installation on elevated platforms without reinforcement.
Paketa e rreshtimit Rezistent ndaj Abrasionit | Baza Teknike: Wear plates of AR400 steel or replaceable polyurethane liners at all impact points (kutia e ushqimit, discharge lips) | Përfitimi Operacional: Protects critical wear areas from rapid degradation caused by abrasive coke flow | Ndikimi i ROI: Lowers longterm capital expenditure on body repairs by protecting the primary chassis.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi i Industrisë | Zgjidhja jonë e ekranit me dridhje të koksit | Avantazhi (% Përmirësimi) |
|||||
| Efikasiteti i shqyrtimit | 8590% efficiency under optimal conditions | Maintains 9295% efficiency via antiblinding technology & optimized Gforce | +58% Rendimenti i produktit |
| Jeta e rrobave të ekranit | 36 months for standard wire cloth in primary sizing | 814 months for specialized polyurethane/clad panels | +100%+ Jeta e shërbimit |
| Annual Maintenance Downtime | 120180 hours per year for drive servicing, cloth changes, and structural repairs | e vlerësuar 4060 hours per year due to modular design & external motor drive | 60% Koha e ndërprerjes |
| Force Transmission to Structure | Deri në 25% of dynamic force transmitted via basic coil spring isolators | <5% force transmitted via highperformance shear mounts or air springs | 80% Vibration Transfer |
| Konsumi i energjisë për ton | Ndryshon shumë; older bruteforce designs operate at fixed high power | Efficient motor design with potential for variable frequency drive (VFD) control | Deri në 15% Përdorimi i Energjisë |
5. SPECIFIKIMET TEKNIKE
Kapaciteti/Vlerësimi: varur nga modeli; standard range from 500 MTPH për 2,500 MTPH of dry coke.
Kërkesat për fuqi: Dual motor drives from 2 x 15 kW në 2 x 55 kW (400/690V, 50/60Hz). Ngasja me frekuencë të ndryshueshme (VFD) opsionale.
Specifikimet e materialit: Mainframe – Carbon steel (ST37/52); Wear surfaces – AR400 steel or premium polyurethane; Screen panels – Polyurethaneclad steel wire or hightensile rubber.
Dimensionet fizike: Typical singledeck unit (gjerësia x gjatësia): p.sh., 2.4m x 6.0m to 3.0m x 9.0m.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 20°C deri në +45°C. Mbulesa të papërshkueshme nga pluhuri të disponueshme për ngasjet e motorëve (IP66). Not rated for explosive atmospheres without additional certification.
6. Skenarët e APLIKIMIT
[Steel Mill – Blast Furnace Feed] Sfida: A major integrated steel mill experienced inconsistent blast furnace burden permeability due to excessive fines (<10mm) in their screened metallurgical coke feed.
[Zgjidhje] Implementation of a customdesigned primary Coke Vibration Screen featuring a twodeck configuration with stringent cut points and aggressive antiblinding panels on the top deck.
[Rezultatet] Fines content in furnace feed was reduced from an average of ~12% to a consistent <7%. This contributed to improved gas flow in the blast furnace, resulting in an estimated ~3% reduction in specific coke rate (kg coke/tonne hot metal).
[Petroleum Coke Processing Plant] Sfida: A petcoke processor faced severe screen cloth blinding within hours when handling material with residual surface hydrocarbons ("sticky petcoke"), requiring multiple daily shutdowns.
[Zgjidhje] Deployment of a specialized Coke Vibration Screen utilizing nonadhesive heated screen decks combined with ultraflexible urethane screen panels.
[Rezultatet] Continuous operating time between blinding events increased from ~8 hours to over one week (~168+ hours), increasing plant availability by approximately two full production days per month.
7. KONSIDERATA TREGTARE
Nivelet e çmimeve: Equipment pricing is structured based on capacity (xhiros), madhësia (deck area), and material specification grade (Standard Duty vs Super HeavyDuty).
Karakteristikat opsionale: Upgrades include stainless steel components for corrosion zones, mbulesat e kapsulimit të pluhurit, skirtboard systems, sensorë të avancuar të monitorimit të gjendjes (dridhje/temperaturë), spray bar systems for controlled dust suppression,
and custom paint systems for harsh environments.
Paketat e Shërbimit: Available packages range from basic commissioning support up through comprehensive annual inspection contracts that include vibration analysis reports,
wear part audits,
and prioritized spare parts provisioning.
Opsionet e financimit: Flexible commercial terms can be discussed,
including outright purchase,
extended payment plans aligned with project milestones,
or leasing structures through thirdparty partners.
8.FAQ
1.P:What if our incoming feed size distribution varies significantly?
A:The dualvibration motor drive allows adjustment of vibration amplitude,
which can be manually tuned
or automated via PLC/VFD control
to adapt Gforce
for different feed conditions while maintaining separation efficiency.
2.Q.How does this equipment integrate with our existing conveyor system?
A.We design inlet heights
and discharge chute configurations
to match your specified interface points.
Detailed layout drawings are provided during the proposal stage
for your engineering team's review.
3.Q.What is the typical lead time?
A.For standard configurations,
lead times range from XX weeks upon order confirmation
and finalization of technical drawings.Customized solutions may require additional engineering time.
4.P.A janë pjesë këmbimi në dispozicion?
A.We maintain an inventory
of critical wear components—such as screen panels,
isolation mounts,
and motor sets—for expedited shipment.A recommended initial spare parts list will be provided.
5.Q.What level of foundation preparation is required?
A.The equipment requires a flat,
level reinforced concrete foundation capable
of supporting its static weight.Detailed foundation load drawings—including static
and dynamic loads—are supplied as part
of our technical documentation package.
6.Q.Can you provide performance guarantees?
A.We offer contractual guarantees on throughput capacity under defined feed conditions
and screening efficiency based on agreedupon particle size distribution data.Previous client field data supports these commitments.
7.Q.Do you offer operator training?
A.Comprehensive training at your site during commissioning is included.This covers safe operation,routine inspection procedures,and basic troubleshooting steps
