1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Hoạt động xử lý than cốc của bạn có bị ảnh hưởng bởi chất lượng sản phẩm không nhất quán không?, phạt quá mức, and unplanned maintenance halts? Dành cho người quản lý nhà máy giám sát sàng lọc than cốc, common challenges directly impact profitability and throughput:
Ô nhiễm sản phẩm & Rejections: Inefficient separation allows undersize fines to contaminate blast furnace feedstock or anodegrade product, leading to customer penalties and degraded metallurgical performance.
Premature Screen Deck Failure: The extreme abrasiveness of hot or cold coke accelerates wear on screen panels and support structures, gây ra thường xuyên, costly replacements and production stoppages.
chói mắt & Chuyển tiếp: Sticky coke particles and moisture can blind screen apertures, trong khi độ rung không đủ dẫn đến sự chuyển vật liệu, drastically reducing effective screening capacity and classification accuracy.
Mệt mỏi kết cấu & Truyền rung: Poorly engineered vibratory motion transmits damaging harmonics to the base frame and surrounding infrastructure, risking longterm structural integrity.

Are you seeking a screening solution engineered not just to move material, but to precisely classify it while withstanding the punishing environment of coke handling? The right bespoke vibration screen is a capital investment in predictable grading and operational continuity.

2. TỔNG QUAN SẢN PHẨM

A Bespoke Coke Vibration Screen is a heavyduty industrial screening machine specifically designed for the sizing, lột da đầu, or dedusting of metallurgical coke (cold or hot) và than cốc dầu mỏ. Engineered from the ground up for this application, it replaces generic screens that fail under abrasive loads.

Quy trình hoạt động:
1. Nguồn cấp dữ liệu được kiểm soát: Coke is introduced via a regulated feed chute onto the screen’s inlet section, distributing load across the full deck width.
2. Phân tầng cường độ cao: A precisely tuned vibratory mechanism (typically dual eccentric shaft or bruteforce design) imparts a linear or elliptical motion, aggressively stratifying material. Fines are forced downward to contact the deck.
3. Tách chính xác: Stratified particles pass through accurately sized screen panel apertures (lưới thép, polyuretan, hoặc tấm đục lỗ), separating into defined size fractions (ví dụ., +50mm, 50mm+25mm, 25mm).
4. Xả hiệu quả: Sized fractions discharge via dedicated chutes into separate collection conveyors or bins for downstream processing.

Phạm vi ứng dụng: Sàng lọc sơ cấp và thứ cấp than cốc luyện kim (blast furnace foundry), than cốc dầu mỏ anodegrade, calcined coke. Suitable for sinter feed preparation and coke breeze recovery.
Hạn chế: Not designed for wet screening processes or as a replacement for crushers. Maximum feed temperature and particle size are defined by specific material specifications.

3. TÍNH NĂNG CỐT LÕI

Hệ thống sàn mô-đun | Cơ sở kỹ thuật: Boltin panel subframes with tensioning rails | Lợi ích hoạt động: Enables rapid changeover of worn screen media (<4 giờ so với. 12+), minimizing downtime for maintenance crews. | Tác động ROI: Reduces labor costs per changeout by ~60% and increases annual available production time.

Hot Coke Design Package | Cơ sở kỹ thuật: Internal aircooled bearing housings & heatresistant seals | Lợi ích hoạt động: Allows continuous operation with coke feed up to 250°C without bearing lubrication failure or seal degradation. | Tác động ROI: Eliminates costly cooling periods before screening, increasing line throughput by maintaining process flow.

Chống chói mắt & Wear Systems | Cơ sở kỹ thuật: Integrated ball tray decks or tensioned wire mesh with polyurethane cleaners | Lợi ích hoạt động: Continuous microimpact dislodges sticky particles; wearresistant liners on decks/sideplates extend service life in highabrasion zones. | Tác động ROI: Maintains nearoriginal capacity over longer campaigns; reduces consumable parts expenditure by 3040% hàng năm.

Dynamically Tuned Vibratory Frame | Cơ sở kỹ thuật: Phân tích phần tử hữu hạn (FEA) phân phối ứng suất tối ưu & isolation spring system | Lợi ích hoạt động: Contains vibratory forces within the screen body; minimizes harmful transmission to supporting structures (<90% isolation efficiency). | Tác động ROI: Protects civil foundation investments and eliminates ancillary structural repairs.

Thiết kế đóng gói bụi | Cơ sở kỹ thuật: Gasketed covers & dusttight discharge spouts with inspection ports | Lợi ích hoạt động: Contains coke dust at transfer points, improving site air quality and reducing housekeeping labor. | Tác động ROI: Lowers environmental compliance risk and reduces cleanuprelated operational delays.

Condition Monitoring Prep | Cơ sở kỹ thuật: Preinstalled sensor pads (rung động, nhiệt độ) on bearings with external junction box | Lợi ích hoạt động: Facilitates easy integration into predictive maintenance programs for early fault detection. | Tác động ROI: Ngăn chặn các hư hỏng vòng bi thảm khốc; enables planned shutdowns, avoiding 70+ hours of unplanned downtime per incident.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Generic Screen) | Giải pháp màn hình rung Coke Bespoke | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Tuổi thọ của bảng điều khiển boong| 36 months under abrasive load| 814 months with applicationspecific media| +130% ĐẾN +150% |
| Hiệu quả sàng lọc| ~85% for 25mm separation| nhất quán >92% for same separation| +8% lợi ích tuyệt đối |
| Thời gian ngừng hoạt động hàng năm để bảo trì màn hình| 120180 giờ (kiểm tra, changes)| 4060 giờ (thiết kế mô-đun)| 65% sự giảm bớt |
| Tiêu thụ năng lượng trên mỗi tấn được sàng lọc| Đường cơ sở (100%)| Khối lượng tối ưu & hiệu quả ổ đĩa| 15% sự giảm bớt |
| Mang MTBF (Thời gian trung bình giữa thất bại)| ~12,000 hours in harsh service| >20,000 hours with cooling/sealing package| +67% sự cải tiến |

Screening Efficiency defined as ratio of correctly sized undersize material recovered vs. total undersize in feed.

5. THÔNG SỐ KỸ THUẬT

Đánh giá năng lực: phụ thuộc vào mô hình; phạm vi tiêu chuẩn từ 200 MTPH đến 1,200 MTPH của than cốc số lượng lớn (80 lbs/ft³).
Đơn vị ổ đĩa: Dual eccentric shaft mechanism with greaselubricated spherical roller bearings. Alternative bruteforce designs available for highcapacity scalping.
Yêu cầu về nguồn điện: 15 kW để 55 động cơ kW (400V/50Hz hoặc theo quy định), IP66 rated.
Cấu hình boong: Đơn, gấp đôi, or tripledeck layouts based on cut points.
Tùy chọn phương tiện màn hình: Lưới thép cacbon cao (hotgalvanized), tấm mô-đun polyurethane, perforated manganese steel plates.
Khung kết cấu: Heavyduty carbon steel plate construction with internal ribbing; shotblasted and coated with industrial epoxy paint system.
Kích thước vật lý (Typical DoubleDeck): Length ~7m x Width ~2.5m x Height ~3m (excluding supports).
Môi trường hoạt động: Được thiết kế cho nhiệt độ môi trường xung quanh từ 20°C đến +50°C; capable of processing material up to 250°C with hot package.

6. KỊCH BẢN ỨNG DỤNG

[Steel Mill Blast Furnace Feed] Thử thách: A major integrated steelmaker experienced high variability in blast furnace coke size fraction (50mm+25mm), leading to irregular gas flow and increased fuel rate penalties estimated at €500k annually.Giải pháp: Implementation of a tripledeck bespoke coke vibration screen with precise aperture control ahead of the furnace bins.Kết quả: Achieved consistent sizing with <3% deviation in target fraction; reduced furnace fuel rate by 2%. Payback period was under 18 months via fuel savings alone.

[Nhà máy nung than cốc dầu mỏ] Thử thách: Anodegrade calciner needed to remove all 8mm fines from final product but faced rapid blinding of standard screens from residual volatiles.Giải pháp: Installation of a bespoke linear motion screen featuring antiblinding ball trays and directheated deck panels.Kết quả: Sustained screening efficiency above 94%; eliminated manual deck cleaning shifts; increased saleable product yield by an estimated 4%.

7. CÂN NHẮC THƯƠNG MẠI

Our Bespoke Coke Vibration Screens are offered in three primary tiers:
1. (Cấp cơ sở): Standard Duty Screens, engineered core components with selectable media options—ideal for lowertonnage operations processing cooled coke.
2. (Cấp độ được đề xuất): HeavyDuty Performance Screens, includes all core features listed above—the standard solution for most highvolume metallurgical applications requiring reliability.
3. (Bậc cao cấp): SevereDuty Engineered Systems, includes full FEA analysis report customised feed/discharge hoods advanced instrumentation packages—specified for greenfield sites maximum operational data capture

Optional features include variable frequency drives process control integration custom skid bases extended warranty packages

Financing options include capital purchase lease agreements operating leases tailored support service packages provide scheduled inspections parts supply

8.Câu hỏi thường gặp

Q1 Is your bespoke vibration screen compatible existing conveyor feed hoppers
Our engineering team will review your existing layout interface drawings We design custom inlet transition sections flanges ensure a proper fit minimal retrofit required during installation

Q2 Thời gian chạy thử cài đặt điển hình là gì
From arrival site mechanical installation electrical connection dry run commissioning typically requires days supervised our engineer Delivery lead times vary based specification

Q3 How does this equipment impact overall plant noise levels
Properly installed isolated screens operate within dB(MỘT) range at meter distance meeting typical industrial environmental standards Acoustic enclosures are available option where required

Q4 What are payment terms delivery
Standard terms progress payment upon order confirmation payment prior shipment balance due upon completion Factory Acceptance Test Major projects may qualify structured milestone payments

Q5 Do you provide wear parts ongoing technical support
We maintain comprehensive inventory critical wear parts offer guaranteed hour dispatch key components Support packages include remote diagnostics annual health checks technician dispatches