Kostoja e prodhuesit e ekranit të dridhjeve të koksit
1. HAPJE NGA PIKA E DIKIMIT
A po përballet operacioni juaj i trajtimit të koksit me pengesa të vazhdueshme dhe kosto të përshkallëzuara? Faza e shqyrtimit është shpesh një pikë kritike e dështimit, directly impacting downstream processing and overall plant profitability. Sfidat e zakonshme përfshijnë:
Verbimi & Transporti: Lagështia dhe grimcat e imta të koksit ngjiten në kuvertën e ekranit, blinding apertures and forcing material to bypass the screening process. This leads to product contamination, inefficient size separation, and increased wear on crushers.
Koha e tepërt joproduktive për mirëmbajtje: Frequent breakdowns of vibratory mechanisms, ndryshimet e rrobave të ekranit, and structural fatigue repairs halt your entire production line. Unplanned downtime in a coke plant can cost tens of thousands per hour in lost throughput.
Konsumi i lartë i energjisë & Stresi strukturor: Inefficient vibration systems draw excessive power while transmitting damaging forces to the support structure. This increases operational costs and creates longterm integrity concerns for the screening station.
Klasifikimi i paqëndrueshëm i produktit: Variable feed rates and inefficient screen action result in offspec product. This can lead to rejected loads from steel mill customers or reduced efficiency in anode baking plants.
Are you evaluating a coke vibration screen manufacturer based on initial cost alone, or are you calculating the total cost of ownership—factoring in uptime, puna e mirëmbajtjes, and energy efficiency?
2. PËRMBLEDHJE E PRODUKTIT: HeavyDuty Coke Vibrating Screen
Kjo pajisje është me kapacitet të lartë, linear motion vibrating screen engineered specifically for the abrasive and demanding environment of met coke and petroleum coke sizing. Its design focuses on reliable separation of coke fractions (p.sh., koks furre shpërthyese, koks arrë, fllad) after crushing.
Rrjedha e punës operative:
1. Feed & Shpërndarja: Koksi i grimcuar futet në kutinë e fortë të ushqimit, which evenly distributes the material across the full width of the primary screen deck.
2. Positive Material Stratification: A dualshaft vibrator assembly generates a forceful linear motion. Ky veprim shtreson shtratin material, forcing fines downward to contact the screen media while conveying oversize along the deck.
3. Ndarja e saktë e madhësisë: Multiple deck levels (në mënyrë tipike 13) equipped with tailored screen panels (rrjetë teli, poliuretani, or perforated plate) separate the coke into precise size fractions (p.sh., +50mm, 50mm+25mm, 25mm).
4. Shkarkimi & Transporti: Correctly sized fractions are discharged via dedicated chutes onto separate conveyors for stockpiling or direct loading.
Fusha e Aplikimit: Dimensionimi parësor dhe dytësor i metalurgjikut (u takua) coke and petroleum (kafshë shtëpiake) coke in steel plants, carbon anode plants, and bulk coke handling terminals.
Kufizimet: Not designed for sticky materials without predrying or specialized deck treatments. Maximum feed size is limited by deck construction and impact resistance.
3. TIPARET THEMELORE
Sistemi modular i kuvertës | Baza Teknike: Independently tensioned panel sections with quickchange clamping | Përfitimi Operacional: Operators can replace worn panels in under 30 minutes per module without specialized tools or cutting torches. | Ndikimi i ROI: Reduces screen cloth downtime by up to 70%, rritja e orëve vjetore të disponueshme të funksionimit.
Dual CounterRotating Shaft Vibrator | Baza Teknike: Two synchronized eccentric shafts generating a linear force vector along the center of mass | Përfitimi Operacional: Provides aggressive material conveyance with minimal vertical force transmission to the support structure. | Ndikimi i ROI: Lowers structural reinforcement costs by up to 40% and reduces bearing stress for longer service intervals.
HeavyDuty Side Plates & Cross Members | Baza Teknike: Analiza e elementeve të fundme (FEA)optimized steel fabrications with continuous welds | Përfitimi Operacional: Withstands constant highimpact loading from large coke lumps without cracking or fatigue failure over a 10+ year design life. | Ndikimi i ROI: Eliminates costly side plate replacement cycles every 23 years common in lighterduty screens.
Asambleja mbajtëse e mbështjellë me pluhur | Baza Teknike: Labyrinth seals combined with positivepressure purge nipples (opsionale) | Përfitimi Operacional: Prevents abrasive coke dust from contaminating vibrator bearings, the most common cause of catastrophic drive failure. | Ndikimi i ROI: Zgjat jetëgjatësinë e shërbimit me një mesatare prej 300%, preventing unplanned stoppages exceeding $15k per incident.
Ngasja me frekuencë të ndryshueshme (VFD) Përputhshmëria | Baza Teknike: Standardized motor mounts and dynamically balanced vibrator assembly for variable speed operation | Përfitimi Operacional: Allows operators to finetune amplitude/frequency for optimal efficiency with varying feed rates or moisture content from a central control room.| Ndikimi i ROI: Optimizes power draw and screening efficiency; field data shows typical energy savings of 1525% versus fixedspeed screens.
Paketa e rreshtimit Rezistent ndaj Abrasionit | Baza Teknike: Bolton wear liners at all impact points made from AR400 steel or equivalent composite materials | Përfitimi Operacional: Protects critical structural components from direct abrasion, preserving structural integrity.| Ndikimi i ROI: Converts potential major structural repairs into simple liner replacements at 20% of the cost.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Industry Standard for Coke Screens | Zgjidhja jonë e ekranit me dridhje të koksit | Avantazhi (% përmirësim) |
| : | : | : | : |
| Koha e ndryshimit të panelit të kuvertës| 48 orë për kuvertë (full weld/bolt) | <2 orë për kuvertë (modular clamp system)| Deri në 75% më shpejt |
| Jetë që mban vibrator (L10)| ~ 8000 12,000 orët e punës| 24,000+ orët e punës (with proper sealing)| ~100200% longer |
| Lodhja strukturore Jeta| Designed for ~60 million stress cycles| FEAoptimized for >100 million stress cycles| ~67% longer design life |
| Efikasiteti i shqyrtimit (6mm ndarje)| Në mënyrë tipike 8590% në kushte ideale| Arrin në mënyrë të vazhdueshme 9295% efikasiteti në testet në terren| ~58% absolute improvement |
| Transmitted Dynamic Force| High dynamic load factor requiring heavy supports| Low dynamic force design via balanced mass system| Deri në 35% less force transmitted |
5. SPECIFIKIMET TEKNIKE
Gama e Kapacitetit: varur nga modeli; standard units handle from 200 MTPH deri në fund 2,500 MTPH of dry crushed coke.
Konfigurimi i kuvertës së ekranit: Beqare, dyfishtë, ose opsionet e trefishtë; gjerësi standarde nga 1.5 m në 3 m; lengths from 4m to over 9m.
Udhëtoni & Fuqia: Dual shaft vibrator driven by twin TEFC motors via Vbelts. Fuqia totale e instaluar varion nga 15 kW në 75 kW depending on size/mass.
Karakteristikat e dridhjeve: Linear stroke typically adjustable between 8mm – 11mm; frequency range of 750 1000 RPM.
Specifikimet e materialit: Korniza kryesore e ndërtuar nga çeliku strukturor S355JR; side plates are often thickergrade S355J2G3; wear surfaces lined with AR400 steel; highstrength alloy steel shafts.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 20°C deri në +50°C; capable of handling material temperatures up to 150°C with specific seal/bearing configurations.
6. Skenarët e APLIKIMIT
Përgatitja e ushqimit për furrën e shpërthimit të fabrikës së çelikut
Sfida: A major integrated steel mill experienced chronic blinding on their secondary coke screens due to seasonal moisture increases. This caused excessive 10mm fines ("fllad") reporting to the BF skip fraction (>12%), disrupting furnace permeability.
Zgjidhje: Installation of two tripledeck linear motion screens featuring nonblinding polyurethane deck panels on lower decks combined with heated deck technology on top decks.
Rezultatet: Screening efficiency for 10mm removal improved from 84% te 96%. Fines content in BF feed stabilized below 5%, duke kontribuar në një të vlerësuar 2% reduction in specific coke rate within six months.
Fabrika e kalcinimit të koksit të naftës
Sfida: An anodegrade calciner needed precise sizing (30mm+15mm) of green petroleum coke but faced rapid wear of wire mesh panels every three weeks due to extreme abrasiveness.
Zgjidhje: Implementation of customdesigned vibrating screens using modular tensioned polyurethane panel systems with ultrahigh abrasion resistance ratings.
Results Screen panel life extended from three weeks to over fourteen weeks between changes Annual maintenance costs for screen media fell by approximately $65k per unit
Bulk Coke Handling Terminal
Challenge A transshipment terminal required highcapacity screening (>2200 MTPH) but had strict limitations on allowable dynamic load transferred into their existing elevated gallery structure
Solution Engineers specified low dynamic force linear motion screens incorporating outofbalance motors configured specifically for force cancellation
Results Required throughput was achieved while transmitted dynamic forces were measured at 28 below the gallery s design limits eliminating need for costly structural reinforcement
Konsiderata Komerciale
Nivelet e çmimeve:
Tier I Standard Duty Units For capacities 1500 MTPH severe duty environments custom materials Quoted per project
Karakteristikat opsionale:
Heated Screen Decks spray bars antiblinding systems
Advanced Sealing Packages including positive air purge systems
Full Stainless Steel Construction contact parts specific corrosion environments
Integrated Condition Monitoring Systems vibration temperature sensors
Paketat e Shërbimit:
Basic Package Standard warranty parts manual
Platinum Support Package Extended warranty priority parts dispatch annual health inspection reports
Full Service Contract Includes all scheduled maintenance parts labor performance audits fixed annual fee
Opsionet e financimit:
Capital Purchase Direct sale outright ownership
Lease To Own Programs Fixed term lease concluding transfer title suitable managing capital expenditure
Operating Lease Lower monthly payments equipment returned end term
FAQ
What if my existing feed chutes support structure don align perfectly with your standard dimensions We provide comprehensive interface drawings during quotation phase can manufacture custom adapter sections transition pieces ensure fit within your current layout at minimal additional cost
How does this screen handle wet sticky coke during rainy seasons While no vibrating screen eliminates all sticky material issues our combination open deck designs optional heated decks significantly reduces adhesion For severe conditions we recommend pre drying steps consult our engineering team specific recommendations
What is realistic expected lifespan main frame structure before major refurbishment Based operational history similar installations our FEA optimized frames show no signs fatigue cracking requiring repair years proper installation maintenance Bearings seals consumable components will require scheduled replacement
Can you supply compatible replacement screen panels our existing competitor s equipment Yes we manufacture tailor made tensioned modular panels fit most major OEM brands often higher wear resistant materials than original specification Provide model number detailed measurements quotation
Do you offer performance guarantees Field data allows us confidently guarantee screening efficiency percentage points specific cut size provided agreed upon consistent feed rate material characteristics Guarantees outlined detail commercial contract
What typical delivery lead time after order confirmation For Tier II heavy duty units standard configuration lead time ranges weeks depending current workload Tier III custom solutions require detailed engineering lead times start weeks Final schedules confirmed upon order
Are installation supervision commissioning services included Basic installation manuals detailed General Arrangement drawings included Optional site supervision commissioning engineer services available fixed daily rate ensure optimal startup performance
