Export Coke Vibration Screen Manufacturing
1. HAPJE NGA PIKA E DIKIMIT
Is your coke handling operation losing profitability to inefficient screening? Common challenges with conventional screens directly impact your bottom line. A jeni duke përjetuar:
Excessive Product Loss: Fines and valuable coke breeze passing through worn or inefficient screen decks, që përfaqëson humbje direkte të të ardhurave me çdo ton të përpunuar.
Kohë joproduktive me mirëmbajtje të lartë: Frequent failures of screen decks, kushinetat, or exciters due to the extreme abrasion and impact of coke, leading to unscheduled stoppages and production delays.
Verbimi & Poor Efficiency: Moisture or sticky fines blinding screen meshes, drastically reducing effective screening area and throughput, forcing recirculation and increasing energy costs.
Klasifikimi i paqëndrueshëm i produktit: Unreliable particle size separation resulting in offspec product for blast furnace or foundry customers, risking contract penalties and reputational damage.
Shqetësimet e integritetit strukturor: Konstante, highimpact vibration leading to fatigue cracks in the screen body or support structure, creating major safety risks and costly capital repairs.
The core question for plant managers is: si mund të arrini saktë, reliable coke classification while maximizing uptime and protecting your material yield?
2. PËRMBLEDHJE E PRODUKTIT
The Export Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the dry classification of metallurgical coke and coke breeze. Designed for robustness in harsh environments, it separates crushed coke into precise size fractions critical for blast furnace efficiency and other industrial processes.
Rrjedha e punës operative:
1. Prezantimi i ushqimit: Sized coke from crushers is evenly distributed onto the feed box of the vibrating screen.
2. Stratifikimi & Ndarja: Intensiteti i lartë, linear or circular vibration stratifies the material bed. Smaller particles descend to contact the screen cloth apertures, ndërsa grimcat më të mëdha udhëtojnë nëpër sipërfaqen e kuvertës.
3. Shkarkimi i fraksionit të madhësisë: Correctly sized particles pass through the screen mesh (nënpërmasa), while oversized particles discharge at the deck end (tepër i madh). Multideck configurations allow for simultaneous separation into several product grades.
Fusha e Aplikimit: Shqyrtimi parësor dhe dytësor i koksit metalurgjik, coke breeze recovery, sizing for sinter plants, and prescreening for gasification processes.
Kufizimet: Nuk është projektuar për aplikime të skanimit të lagësht ose për materiale me veti ngjitëse ekstreme pa trajtime të specializuara të kuvertës.
3. TIPARET THEMELORE
Sistemi modular i kuvertës | Baza Teknike: Topat, subframe mounted polyurethane or rubber clad steel panels | Përfitimi Operacional: Dramatically reduced replacement time; individual panels can be changed without full deck dismantling. | Ndikimi i ROI: Shkurt kohën e planifikuar të mirëmbajtjes deri në 60%, rritjen e orëve vjetore të punës.
HeavyDuty Exciter Assembly | Baza Teknike: Montuar brenda, greaselubricated vibrator unit with oversized bearings and labyrinth seals | Përfitimi Operacional: Isolated from direct material impact; delivers consistent amplitude under variable load conditions. | Ndikimi i ROI: Proven service intervals exceeding 8,000 orë në punë të vazhdueshme, reducing spare part consumption.
Ndërtimi i HuckBolted | Baza Teknike: Highshear strength fastener system used throughout the main frame and side plates | Përfitimi Operacional: Eliminates weld fatigue failures; creates a rigid, maintenancefree body structure resistant to crack propagation. | Ndikimi i ROI: Zgjat jetën e shërbimit strukturor me vite, duke shmangur kostot e parakohshme të zëvendësimit të kapitalit.
Tiered Dust Enclosure | Baza Teknike: Multisegment rubber skirtboard system with quickrelease clamps at multiple transfer points | Përfitimi Operacional: Contains dust emission at feed, shkarkimi, and side skirts; improves plant environmental compliance. | Ndikimi i ROI: Mitigates material loss as airborne fines and reduces housekeeping labor requirements.
Suspension pranveror i akorduar | Baza Teknike: Computermodeled coil spring or rubber buffer system matched to dynamic load parameters | Përfitimi Operacional: Izolohet deri në 85% të forcave dinamike nga struktura mbajtëse; allows installation on elevated platforms. | Ndikimi i ROI: Eliminates costly structural reinforcement needs during installation and minimizes vibration transmission.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi i Industrisë (Ekrane konvencionale) | Export Coke Vibration Screen Solution | Avantazhi (% përmirësim) |
| : | : | : | : |
| Jetëgjatësia e panelit të kuvertës| 36 months with steel wire mesh | 1218 months with polyurethane clad panels | +150% përmirësim mesatar |
| Disponueshmëria vjetore| ~8590% (duke përfshirë ndalesat e planifikuara)| >94% (të dhënat e dokumentuara në terren) |>4 fitim pikë përqindjeje |
| Efikasiteti i shqyrtimit| 8590% on dry 6mm separation| Në mënyrë të vazhdueshme >94% on same duty| +5% reduction in misplaced fines |
| Konsumi i energjisë për ton| Baza bazë (100%)| Makinë e optimizuar & bilanci i masës zvogëlon tërheqjen me ~ 15%| 15% lower operational cost |
| Instalimi & Koha e komisionimit| 57 days for full assembly on site| Preassembled modules reduce field work to 23 ditë|<50% of standard time |
5. SPECIFIKIMET TEKNIKE
Kapaciteti / Vlerësimi: Në varësi të modelit; variojnë nga 500 MTPH për 2,500 MTPH of dry coke (bulk density ~0.50.6 t/m³).
Kërkesat për fuqi: Drejtoni motorët nga 15 kW në 45 kW për njësi vibrator (zakonisht dualdrive), 400/690V dhe, IP66 protection standard.
Specifikimet e materialit:
Korniza në kuvertë & Pllaka anësore: Çeliku rezistent ndaj gërryerjes (AR400/450).
Kuvertën e ekranit: Modular polyurethane panels with embedded steel reinforcement; optional rubberclad steel or tensioned wire cloth.
Korniza kryesore & Cross Members: Heavywalled structural steel with corrosioninhibiting primer.
Dimensionet fizike: Singledeck widths from 1.8m to 3.6m; gjatësia nga 4.8m në 7.2m.
Gama e funksionimit të mjedisit: Temperatura e ambientit nga 20°C deri +45°C; designed for outdoor installation with appropriate electrical components.
6. Skenarët e APLIKIMIT
Integrated Steel Plant Blast Furnace Feed
Challenge A major steel producer faced consistent fines (5mm) contamination in their BFgrade coke (2575mm), affecting furnace permeability and increasing coke rate.
Solution Installation of a primary Export Coke Vibration Screen with two decks following secondary crushing.
Results Achieved a clean +25mm product with less than 3% undersize contamination while recovering 5mm breeze for sinter plant use—a quantifiable reduction of $12/ton in effective BF feed cost.
Prodhues i koksit tregtar
Challenge Offspec product batches due to inconsistent screening after rain events caused moistureinduced blinding on traditional screens.
Solution Implementation of our screens equipped with specialized antiblinding polyurethane decks featuring slotted apertures and balltray cleaning systems.
Results Screening efficiency remained above 92% even with surface moisture up to 7%, eliminating penalty clauses related to product sizing in supply contracts within one quarter.
7 KONSIDERATA TREGTARE
Export Coke Vibration Screens are offered in three primary tiers:
1. Seria standarde e detyrës: Për kapacitete deri në ~800 MTPH. Includes core heavyduty construction features ideal for most merchant coke operations.
2. Seria e detyrës së rëndë: For capacities from ~800 MTPH to ~1,800 MTPH featuring enhanced exciter specifications and premiumtier bearing assemblies—the recommended choice for integrated steel plants.
3. Seritë Extra Heavy Duty: For ultrahighcapacity applications exceeding ~1，800 MTPH， incorporating duplex bearing exciters， dizajni i kornizës së përforcuar，and premium dust sealing packages．
Optional features include stainless steel fasteners，full stainless steel skirting，integrated spray systems for limited dust suppression，and condition monitoring sensor ports．
Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including scheduled inspections，analiza e dridhjeve，and guaranteed spare parts availability．Financing options including equipment leasing are available through accredited partners．
FAQ
Q What is the lead time for a typical Export Coke Vibration Screen?
A Lead times vary by model complexity．For standard configurations，expect delivery within X weeks upon order confirmation．Customized solutions may require additional engineering time．
Q Can this equipment integrate into our existing PLCcontrolled plant？
A Yes．All drives are compatible with standard industrial motor starters．The screen itself is supplied readyforsignal connection；it does not include complex control logic but can interface with your plant’s start/stop interlocks．
Q How does this design handle variations in feed rate？
A The exciter system generates a constant force independent of load．While efficiency is optimized at design capacity，field data shows performance degradation remains minimal (±2%) within a ±20% feed rate fluctuation．
Q What are the primary wear items？
A The primary consumables are the modular deck panels followed by wear liners on feed boxes．Spare parts kits based on recommended annual usage are available．
Q Do you provide installation supervision？
A Yes．Professional commissioning supervision is offered as an optional service package．This includes final alignment checks，initial startup assistance，and operator training．
Q Are your technical specifications guaranteed？
A All performance figures stated are based on standard test conditions using defined material characteristics．We provide written performance guarantees as part of our commercial proposal based on your specific application data sheet．
Q What financing structures do you offer？
A We work with thirdparty financial institutions that offer operating leases，capital leases/finance leases,and traditional purchase loans.Structures can be tailored over terms typically ranging from X years
