Coke Vibration Screen Manufacturer Testing
1. HAPJE NGA PIKA E DIKIMIT
Is your coke screening operation plagued by persistent, joefikasiteti i kushtueshëm? Për menaxherët e impianteve dhe kontraktorët inxhinierikë, the challenges of screening bulk metallurgical coke directly impact throughput, cilësinë e produktit, and bottomline profitability. Pengesat e zakonshme operacionale përfshijnë:
Verbimi & Transporti: Fine coke breeze and moisture cause screen mesh blinding, reducing effective screening area. Njëkohësisht, undersize material carries over with the product stream, contaminating blast furnace feed and degrading its performance.
Kohë joproduktive të mirëmbajtjes së tepërt: The abrasive nature of coke accelerates wear on screen decks, pllaka anësore, and exciters. Frequent component replacement leads to unplanned downtime and high spare parts inventories.
Ndarja joefikase e gjobave: Inadequate separation of the 010mm fraction results in lost revenue from breeze sales and inefficient recycling within the coke plant.
Structural Fatigue & Dështimi: High Gforces from traditional vibrators transfer damaging stress to the screen body and support structure, leading to weld cracks and catastrophic frame failures.
Konsumi i lartë i energjisë: Inefficient drive systems and oversized motors run continuously, contributing to significant, nonproductive power costs.
Are you seeking a solution that reduces downtime by 30% or more while ensuring consistent product sizing? The answer lies in selecting a coke vibration screen engineered specifically to overcome these materialspecific challenges.
2. PËRMBLEDHJE E PRODUKTIT
The equipment in focus is a heavyduty Coke Classification Vibrating Screen, designed for highcapacity sizing of hot or cold metallurgical coke (25mm 80mm) from oven discharge and the subsequent separation of coke breeze (0mm 10mm).
Rrjedha e punës operative:
1. Feed & Shpërndarja: Bulk coke is uniformly fed onto the robust feed box, which distributes the material across the full width of the primary screen deck.
2. Primary Sizing: A highstrength wire mesh or punch plate deck performs the primary separation, allowing undersize material (breeze and small fractions) to pass through.
3. Ekzaminimi sekondar & Heqja e gjobave: A second deck further refines the separation, ensuring maximum recovery of marketable coke breeze.
4. Shkarkimi: Correctly sized foundry or blast furnace coke discharges from the screen end, while separated fines are collected via a dedicated chute for processing or sale.
Fusha e Aplikimit & Kufizimet:
This equipment is designed for dry or slightly moist coke screening in fixed plant installations. It is not suitable as a replacement for rotary breakers or for handling highly sticky materials without pretreatment. Maximum lump size should not exceed 150% of the nominal top deck aperture.
3. TIPARET THEMELORE
Sistemi modular i kuvertës | Baza Teknike: Topat, pretensioned panel design with polyurethane side tensioning strips | Përfitimi Operacional: Individual deck sections can be replaced in under 2 hours without welding or specialized tools, minimizing downtime for maintenance. | Ndikimi i ROI: Reduces screen cloth changeout time by up to 60%, duke rritur drejtpërdrejt disponueshmërinë e impiantit.
Teknologjia DualMass Drive | Baza Teknike: Two synchronized counterrotating masses generating a linear stroke | Përfitimi Operacional: Transfers dynamic forces into the screening motion rather than the support structure; allows for lower horsepower motors due to efficient energy transfer. | Ndikimi i ROI: Cuts structural maintenance costs by an estimated 40% and reduces operational energy consumption by 1525%.
Paketa e rreshtimit Rezistent ndaj Abrasionit | Baza Teknike: Bolton wear plates made from AR400 steel at all critical impact points (kutia e ushqimit, discharge lips) | Përfitimi Operacional: Protects the main screen frame from wear, extending its service life beyond 10 years under typical conditions. | Ndikimi i ROI: Eliminates need for frequent frame repair or replacement, providing a predictable longterm asset cost.
Environmental Sealing System | Baza Teknike: Multistage labyrinth seals combined with durable rubber dust curtains at transfer points | Përfitimi Operacional: Contains dust emissions at source, improving site environmental compliance and operator health conditions. | Ndikimi i ROI: Lowers costs associated with airborne particulate control and reduces housekeeping labor.
Tuned Spring Isolation | Baza Teknike: Computermodeled coil spring or rubber shear mount system matched to screen weight and operating frequency | Përfitimi Operacional: Isolates up to 95% of dynamic vibration from the supporting structure, preventing damage to building foundations and adjacent equipment. | Ndikimi i ROI: Eliminates secondary structural costs and prevents costly vibrationinduced failures in plant infrastructure.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi i Industrisë | Coke Vibration Screen Solution | Avantazhi (% përmirësim) |
| : | : | : | : |
| Koha e zëvendësimit të panelit të kuvertës| 68 orë (welded) | <2 orë (bolted modular) | ~ 70% më shpejt |
| Lodhja strukturore Jeta| 35 years before major repair| 8+ years with protected frame| >100% rriten |
| Efikasiteti i shqyrtimit (Breeze Removal)| ~85% efficiency| Në mënyrë të vazhdueshme >92% efikasiteti| ~8% more product recovery |
| Operating Noise Level| 95105 dB(A) dhe 1 m| <85 dB(A) dhe 1 m| ~15 dB reduction |
| Annual Power Consumption| Baza bazë (100%) for same duty| Reduced motor size + makinë efikase| 1525% reduktim |
5. SPECIFIKIMET TEKNIKE
Vlerësimi i Kapacitetit: varur nga modeli; standard range from 300 MTPH për 1,200 MTPH of bulk coke (bulk density ~0.5 t/m³).
Kërkesat për fuqi: Driven by dual lowvoltage AC motors (p.sh., 2 x 11 kW në 2 x 30 kW), depending on model size and stroke configuration.
Specifikimet e materialit:
Kornizë: Çeliku i karbonit të rëndë (S355JR), të çliruar nga stresi.
Kuvertë: Options include highcarbon steel wire mesh (65Mn), HARDOX® punch plates, or polyurethane panels.
Mbrojtje ndaj veshjes: AR400 steel liners standard at all impact zones.
Dimensionet fizike: Typical singledeck unit footprint ranges from (L)6m x (W)2.5m x (H)1.8m to (L)9m x (W)3.5m x (H)2m.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 20°C deri në +50°C; capable of handling hot coke up to ~200°C with appropriate deck material selection.
6. Skenarët e APLIKIMIT
Integrated Steel Plant Coke Oven Battery Discharge
Sfida: A major steel producer faced severe blinding on their existing screens due to residual moisture in quenched coke. This caused frequent overloads on downstream crushers and inconsistent blast furnace feed sizing (+/15variancë mm).
Zgjidhje: Implementation of two parallel heavyduty linear motion Coke Vibration Screens featuring nonblinding balltray decks on the fines removal section.
Rezultatet: Screening efficiency stabilized at ≥94%. Oversize contamination was eliminated (<1%), protecting crusher integrity. The consistent product sizing contributed to a documented ~3% improvement in blast furnace burden permeability.
Merchant Coke Producer – Breeze Recovery
Sfida: A merchant plant was losing significant revenue due to poor fines capture; an estimated 810% of saleable breeze was being incorrectly routed back into crusher feed circuits as "circulating load."
Zgjidhje: Retrofitting a dedicated Coke Vibration Screen with a finemesh secondary deck into their product classification circuit postcrushing.
Rezultatet: Breeze recovery increased from ~82% to over 95%, creating an additional revenue stream exceeding project payback within one year based on market prices for fuelgrade fines.
7.KONSIDERATA TREGTARE
Ekranet tona të dridhjeve të koksit ofrohen në tre nivele kryesore:
Seria standarde e detyrës: For capacities up to ~500 MTPH with robust base specifications; ideale për impiante më të vogla ose për cikle pune më pak të rënda.
Seria HeavyDuty (>500 MTPH): Our most common specification featuring all core technologies listed above; designed for continuous operation in integrated steel plants.
Zgjidhje të krijuara me porosi: For unique layouts requiring multiple discharge points specific grades like nut coke separation
Karakteristikat opsionale përfshijnë:
Enclosed designs with integrated dust extraction flanges
Stainless steel components for highly corrosive environments
Sensorë të avancuar të monitorimit të gjendjes
Drejtues me frekuencë të ndryshueshme
Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including guaranteed spare parts availability Financing options including leasing are available through our partners
FAQ
What is your typical lead time?
For standard HeavyDuty Series models lead time is typically between weeks depending on current production schedules Custom engineered solutions require additional engineering time
Are your screens compatible with our existing chutes?
Our engineering team will review your existing layout drawings We provide detailed interface specifications including loads connection points ensuring seamless integration into your current transfer system
How do you guarantee performance?
Performance guarantees are based on agreedupon feed material characteristics We provide certified capacity curves based on laboratory testing data Guarantees typically cover throughput capacity under specified conditions
What does commissioning involve?
Our standard package includes supervision installation mechanical alignment initial startup process tuning We ensure correct operation before handover Documentation includes detailed manuals training materials
What are payment terms?
Standard commercial terms involve progress payments tied key milestones Typically % upon order % before shipment balance upon completion satisfactory commissioning Letters credit accepted Financing options available upon request
Lini Mesazhin Tuaj
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