Importues i personalizuar i ekranit të dridhjeve të koksit
H1: HighCapacity Custom Coke Vibration Screens for Precision Sizing and Scalping
1. HAPJE NGA PIKA E DIKIMIT
Managing coke feedstock quality presents persistent challenges that directly impact downstream process efficiency and plant profitability. A po luftoni me:
Sizing Inconsistencies: Variable feed leading to offspec product, causing rejections or penalties from blast furnace operators.
Gjenerimi i gjobave të tepërta: Conventional screening methods contributing to excessive breakage of highvalue lump coke, eroding yield and revenue.
Kohë joproduktive të paplanifikuara: Frequent screen cloth changes and structural fatigue from abrasive coke abrasion, resulting in costly production halts.
Scalping Inefficiencies: Inadequate removal of oven debris (silicon carbide, "oven stone") and oversized material, risking damage to crushers and conveyors.
Barra e lartë e mirëmbajtjes: Kushinetat, burimet, and decks failing prematurely under heavy loads, driving up spare parts costs and labor hours.
If these operational costs are affecting your bottom line, the specification of your screening equipment is a critical leverage point. Një qëllim i projektuar Custom Coke Vibration Screen is not merely a commodity filter; it is a core component for achieving grade control, protecting capital equipment, dhe maksimizimi i xhiros.
2. PËRMBLEDHJE E PRODUKTIT
A Custom Coke Vibration Screen is a heavyduty vibratory screening machine specifically engineered for the dry separation and classification of metallurgical coke. Dizajni i tij i jep përparësi qëndrueshmërisë, accurate particle separation, and highvolume handling in harsh environments.
Rrjedha e punës operative:
1. Prezantimi i ushqimit: Raw coke from the quench car or storage is conveyed onto the screen's robust feed box.
2. Stratifikimi & Ndarja: A highenergy, linear or elliptical vibratory motion stratifies the material bed. Smaller particles pass through precisely sized screen deck apertures.
3. Shkarkimi i fraksionit: Correctly sized lump coke discharges from the deck end as product. Undersize (fllad koks) passes through to a separate collection chute. Oversize material or scalped debris exits via a dedicated reject spout.
Fusha e Aplikimit & Kufizimet:
Fushëveprimi: Primary sizing of hot or quenched metallurgical coke, scalp removal of oven debris (SiC), heqjen e pluhurit (heqja e erës), and routing of multiple product fractions. Suitable for sinter plant feed preparation.
Kufizimet: Not designed for wet screening applications or for materials with high moisture content that causes blinding. Maximum capacity is defined by physical aperture size and material bulk density.
3. TIPARET THEMELORE
Sistemi modular i kuvertës | Baza Teknike: Independently tensioned panel frames | Përfitimi Operacional: Allows for rapid replacement of individual screen sections without full deck shutdown | Ndikimi i ROI: Zvogëlon kohën e mirëmbajtjes deri në 60% per changeout
Paketa e rreshtimit Rezistent ndaj Abrasionit | Baza Teknike: Bolton AR steel plates in highwear zones (kutia e ushqimit, buzët e shkarkimit) | Përfitimi Operacional: Mbron çelikun strukturor nga konsumimi, extending mainframe service life by multiples | Ndikimi i ROI: Eliminates costly structural repair campaigns; defers capital replacement
Izolimi i pranverës me spirale HeavyDuty | Baza Teknike: Progressiverate steel coil springs | Përfitimi Operacional: Absorbs dynamic loads while transmitting minimal vibration to the support structure | Ndikimi i ROI: Reduces foundational stress cracks and associated civil maintenance costs
Centralized Greasing Lube System | Baza Teknike: Manifold with lines to all bearing points | Përfitimi Operacional: Ensures consistent lubrication of vibrator shaft bearings under high thermal stress | Ndikimi i ROI: Zgjat jetën e shërbimit të kushinetave; prevents catastrophic failure causing extended unplanned downtime
Variable Amplitude & Frequency Drive | Baza Teknike: Adjustable eccentric weights & VFD motor control | Përfitimi Operacional: Operators can tune screen motion for optimal stratification with varying feed rates or coke characteristics | Ndikimi i ROI: Maintains screening efficiency across shifts, maximizing consistent product yield
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Zgjidhja standarde e industrisë | Zgjidhje e personalizuar e ekranit të dridhjeve të koksit | Avantazhi (% Përmirësimi) |
| : | : | : | : |
| Jeta e rrobave të ekranit (Lump Deck) | Standard woven wire mesh | Reinforced polyurethane panels with steel backing grid | +150200% jetëgjatësia |
| Duke MTBF (Koha mesatare ndërmjet dështimit) | ~8,000 hours in harsh service | >12,000 hours with specialized sealing & lube systems| +50% besueshmëria operacionale |
| Screening Efficiency at 80mm cut point| ~8590% efficiency| Në mënyrë të vazhdueshme >94% efficiency via optimized throw & këndi| +59% more product on spec |
| StructureBorne Vibrations Transmitted to Support| Significant harmonic vibration observed| Isolated via tuned spring system & subframe design| Reduktimi i >70% measured vibration |
| Kostoja totale e pronësisë (5periudhës së vitit)| High consumable & repair costs| Predictable maintenance schedule with protected structure| E dokumentuar 2535% lower TCO |
5. SPECIFIKIMET TEKNIKE
Vlerësimi i Kapacitetit: Modele nga 500 TPH te 2,500+ TPH capacity for metallurgical coke (dendësia e masës ~0,5-0,7 t/m³).
Kërkesat për fuqi: Driven by 15 kW në 45 kW vibrator motors (depending on size), standard 400/690V AC supply.
Specifikimet e materialit: Mainframe constructed from heavyduty S355JR steel; critical wear areas lined with Hardox 400/500 ose pllakë ekuivalente AR; corrosionresistant paint system.
Dimensionet fizike: Single or doubledeck configurations; typical deck widths from 1.8m to 3.6m; gjatësia nga 4.8m në 7.2m.
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 heatresistant components.
6. Skenarët e APLIKIMIT
Integrated Steel Plant Blast Furnace Feedstock Preparation
Sfida: A major mill faced inconsistent blast furnace performance linked to variable coke size distribution and periodic contamination from oven debris.
Zgjidhje: Installation of a primary scalping Custom Coke Vibration Screen with a coarse top deck for debris removal and a lower sizing deck.
Rezultatet: Achieved consistent lump coke sizing (>80mm) me <2% oversize/undersize variability; eliminated downstream crusher damage events; regjistruar a 1.5% reduction in blast furnace coke rate within one quarter.
Merchant Coke Producer Yield Optimization
Sfida: The client's existing screens generated excessive fines (10mm breeze), converting highvalue lump product into lowerrevenue streams.
Zgjidhje: Implementation of a twindrive Custom Coke Vibration Screen featuring polyurethane decks designed for reduced abrasioninduced breakage.
Rezultatet: Fines generation reduced by an average of 18%; lump coke yield increased correspondingly, directly boosting annual revenue by an estimated $1.2M at prevailing market prices.
7 KONSIDERATA TREGTARE
Equipment pricing tiers are determined by size/capacity (deck surface area), specifikimet e materialit (standard vs premium AR linings), konfigurimi i diskut (single vs dual), and control sophistication (basic vs PLCintegrated).
Karakteristikat opsionale:
Dust encapsulation hoods
Aircooled vibrator units
Sensorë të avancuar të monitorimit të gjendjes (dridhje/temperaturë)
Komponentët prej çeliku inox për mjedise shumë korrozive
Paketat e shërbimit zakonisht përfshijnë:
Extended warranty plans covering bearings and structural integrity
Inspektimi vjetor & vibration analysis programs
Onsite training for operation & mirëmbajtje parandaluese
Financing options available include capital purchase through project finance partners or longterm operating lease agreements designed to preserve capital budgets.
8 FAQ
Q1 Are your screens compatible with existing conveyor layouts?
A1 Our engineering team designs custom feed boxes discharge heights based on your specific layout drawings ensuring seamless integration into your current transfer points
Q2 Cili është ndikimi i pritur në nivelet e përgjithshme të zhurmës sime të impiantit?
A2 Field data shows our fully isolated designs typically operate below dB(A) levels specified by most industrial health standards reducing noise pollution concerns
Q3 How does this solution address screen blinding issues common with sticky materials?
A3 While primarily dry screens we offer optional deck heating systems ball tray decks antiblinding devices tailored if minor moisture is present
P4 Cilat janë kohët tipike të ofrimit?
A4 Lead times vary based on complexity Standard configurations require weeks while fully customized units require weeks following finalized engineering approval
Q5 A mund të jepni garanci për performancën??
A5 Yes we provide contractual guarantees on throughput capacity screening efficiency based on agreedupon feed material analysis
Q6 What spare parts inventory do you recommend?
A6 We provide a critical spares kit recommendation list including tensioning hardware specialized gaskets drive belts ensuring minimal waiting time for common wear items
