1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Hoạt động xử lý than cốc của bạn có đang gặp khó khăn với tình trạng tắc nghẽn dai dẳng không?, phạt quá mức, và chi phí bảo trì ngoài kế hoạch? Việc sàng lọc không hiệu quả ảnh hưởng trực tiếp đến lợi nhuận của bạn thông qua việc thất lạc sản phẩm, tăng tiêu thụ năng lượng cho các quá trình hạ nguồn, và thời gian ngừng hoạt động tốn kém để thay thế sàn màn hình. Bạn hiện đang phải đối mặt:

Chuyển khoản tiền phạt cao: Ineffective separation leading to valuable coke breeze contaminating the product stream, giảm sản lượng tổng thể và trọng tải có thể bán được.
Frequent Screen Blinding & Thời gian ngừng hoạt động: Moisture and sticky fines clogging screen apertures, requiring frequent shutdowns for manual cleaning or deck replacement, tạm dừng toàn bộ dây chuyền xử lý của bạn.
Mặc thiết bị quá mức: Uncontrolled vibration and impact from oversized material or poor feed distribution accelerating wear on screen panels, kết cấu hỗ trợ, and springs.
Phân loại sản phẩm không nhất quán: Fluctuating feed rates or improper screening action resulting in offspec product that fails to meet stringent customer or internal blast furnace specifications.
Chi phí hoạt động cao: The cumulative effect of these issues—lost production, high maintenance labor costs, and premature component failure—erodes plant profitability.

The solution lies in specifying a vibration screen engineered explicitly for the abrasive, highimpact demands of coke classification. The right equipment transforms these operational challenges into controlled efficiency.

2. TỔNG QUAN SẢN PHẨM

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the precise size separation of metallurgical coke and coke breeze. Its primary function is to ensure a clean, onspec product while maximizing throughput and minimizing fines loss.

Quy trình hoạt động:
1. Nguồn cấp dữ liệu được kiểm soát: Sized coke from the crusher or cooler is delivered onto the screen via a regulated feed box to ensure even distribution across the full width of the screening surface.
2. HighIntensity Separation: A robust vibrator assembly (exciters or unbalanced motors) imparts a linear or elliptical motion to the screen box. This action stratifies the material, forcing undersize particles (gió cocacola) through the defined screen panel apertures.
3. Positive Material Discharge: Chất liệu ngoại cỡ (sản phẩm than cốc) travels along the deck length and discharges at the end of the screen, while undersize material is collected in a hopper beneath the decks for separate conveyance.

Phạm vi ứng dụng & Hạn chế:
This equipment is specifically designed for hot or cold coke sizing in coke handling plants, hệ thống sạc lò cao, and anode production facilities. It is not suitable for wet screening applications without significant modification or for processing materials with drastically different bulk densities and abrasiveness without a full engineering review.

3. TÍNH NĂNG CỐT LÕI

Hệ thống hỗ trợ boong HeavyDuty | Cơ sở kỹ thuật: Reinforced crossmembers with bolted, modular panel attachment | Lợi ích hoạt động: Eliminates panel flexing and fatigue failure under heavy load; allows for rapid, individual panel replacement without welding | Tác động ROI: Giảm thời gian ngừng hoạt động của việc thay boong lên tới 60% so với hệ thống hàn.
Công nghệ sàn chống mù | Cơ sở kỹ thuật: Polyurethane or rubberclad screen panels with flexible, khẩu độ tự làm sạch | Lợi ích hoạt động: Minimizes adhesion of moist fines; panels flex with each vibration cycle to dislodge trapped particles | Tác động ROI: Maintains consistent throughput and grading quality, reducing cleaning shutdown frequency.
DualVibrator Synchronization | Cơ sở kỹ thuật: Two externally mounted exciters synchronized via a gear coupling drive | Lợi ích hoạt động: Cung cấp ổn định, linear vibration force across the entire screen box width; allows for easy adjustment of amplitude | Tác động ROI: Ensures uniform screening efficiency and extends bearing life through balanced load distribution.
SubResonant Spring Isolation | Cơ sở kỹ thuật: Screen box mounted on highcycle composite rubber springs or steel coil springs tuned below resonance frequency | Lợi ích hoạt động: Cách ly lên đến 95% của lực động từ kết cấu đỡ; allows installation on elevated platforms without major structural reinforcement | Tác động ROI: Lowers installation costs and prevents vibration damage to surrounding infrastructure.
Gói lót chống mài mòn | Cơ sở kỹ thuật: Wear plates lined with AR400 steel at all critical impact points (hộp thức ăn, xả môi) | Lợi ích hoạt động: Protects the main screen body from direct abrasion by coarse coke | Tác động ROI: Extends structural life of the main asset by years, deferring major capital expenditure.
Enclosed Dust Sealing System| Cơ sở kỹ thuật: Continuous rubber sealing strips between decks and around access doors| Lợi ích hoạt động: Contains dust emissions at transfer points for a cleaner, safer working environment| Tác động ROI: Reduces housekeeping labor and aids in compliance with plant environmental standards.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành | Giải pháp màn hình rung Coke | Lợi thế (% sự cải tiến) |
| : | : | : | : |
| Tuổi thọ của bảng điều khiển boong | 36 tháng (thép tiêu chuẩn) | 918 tháng (modular polyurethane/AR combo) | +100% ĐẾN +200% |
| Hiệu quả sàng lọc (for target size)| ~8590% | Nhất quán 9396% efficiency maintained over time due to antiblinding tech| +5% lợi ích tuyệt đối |
| Thời gian ngừng hoạt động hàng năm để bảo trì màn hình| 80120 giờ/năm (dọn dẹp & changes) | 3050 giờ/năm (modular changes only)| ~60% giảm |
| Vibration Transmission to Structure| Có ý nghĩa; often requires stiffening| Tối thiểu (90% isolation |
| Amplitude Adjustment Process| Requires adding/removing eccentric weights; downtime needed| External adjustment via variable counterweights or motor speed control; operational adjustment possible.| Time savings >75% per adjustment |

5. THÔNG SỐ KỸ THUẬT

Dung tích & Đánh giá: Được thiết kế cho thông lượng từ 50 TPH đến 1,200+ TPH depending on model size and aperture selection.
Yêu cầu về nguồn điện: Được điều khiển bởi động cơ rung kép từ 2 x 7.5 kW để 2 x 45 kW (400/690V., 50/60Hz). Drive motor requirements vary by model.
Thông số vật liệu: Main frame Carbon steel (ST37). Wear surfaces Replaceable AR400 steel liners. Screen panels Modular polyurethane rubber tensioned panels OR perforated steel plate panels with abrasionresistant treatment.
Kích thước vật lý: Đơn, gấp đôi, hoặc cấu hình tripledeck có sẵn. Typical widths from 1.2m to 3.6m; lengths from 4m to 10m inclusive of feed/discharge boxes.
Phạm vi hoạt động môi trường: Được thiết kế cho nhiệt độ môi trường xung quanh từ 20°C đến +50°C. Handles material temperatures up to ~150°C continuously with appropriate component specifications.

6. KỊCH BẢN ỨNG DỤNG

Blast Furnace Coke Screening Plant

Challenge A major integrated steel mill experienced excessive fines (<10mm) in their blast furnace feed stock due to degraded screenscreen decks blinding daily through moisture ingress causing inconsistent sizing that risked furnace permeability
Solution Installation of two tripledeck Coke Vibration Screens featuring selfcleaning polyurethane panels on top/middle decks combined with high open area wire mesh bottom decks
Results Achieved consistent product grading with <2% fines carryover eliminated two daily manual cleaning shifts reduced annual maintenance hours by over four hundred

Coke Breeze Recovery Circuit

Challenge An independent coke producer was losing significant revenue as valuable breeze was being misdirected into waste streams due an inefficient singledeck vibrating screen
Solution Implementation of a dedicated doubledeck fine Coke Vibration Screen equipped with specialized ball tray decks prevent blinding on fine mesh apertures
Results Recovered an additional metric tons per hour saleable breeze increasing annual revenue by over fifteen percent achieving full payback within eight months

Anode Grade Coke Sizing

Challenge A carbon plant required extremely tight particle size distribution control but their existing screens produced excessive attrition generating unwanted ultrafines during classification process
Solution Commissioning customengineered lowattrition linear motion Coke Vibration Screens featuring gentle material handling low stroke/highfrequency design combined cascading deck arrangement
Results Reduced generation minus fraction by thirty percent while meeting stringent topsize cut point specification improving downstream paste mixing consistency

CÂN NHẮC THƯƠNG MẠI

Pricing tiers are primarily determined by machine size deck count features:
Base Model Tier Standard duty construction fixed amplitude vibrators conventional steel panels suitable lower capacity replacement applications
Performance Tier Includes antiblinding decks adjustable amplitude vibrators composite spring isolation extended wear linings recommended new installations major upgrades
Premium Tier Full custom engineering including special materials dust suppression hoods advanced monitoring sensors predictive maintenance integration

Optional Features Include spray systems dust encapsulation covers variable frequency drives remote monitoring kits different panel types access platforms walkways

Service Packages Available as factory commissioning multiyear parts kits annual inspection contracts full maintenance agreements ensuring operational readiness

Financing Options Flexible acquisition models include outright purchase capital lease operating lease structures tailored support project financing large capital projects

Câu hỏi thường gặp

What is typical lead time delivery new Coke Vibration Screen?
Lead times vary based complexity customization standard designs typically available within weeks fully customized units may require months detailed engineering fabrication commence upon order approval

Can this equipment integrate existing conveyor feed system?
Yes screens are engineered accept standard belt conveyor feeds require properly designed feed box ensure even distribution across full width maximize efficiency prevent localized wear

How does power consumption compare older screening equipment?
Modern designs focus energy efficiency direct drive exciters premium efficiency motors typically result similar marginally lower consumption compared older units while delivering significantly higher throughput reliability

What key factors determining correct screen size my application?
Primary factors are total required tonnage per hour desired separation sizes percentage open area selected panels material bulk characteristics consultation application engineer essential specify correctly

Phụ tùng thay thế có sẵn không?
Manufacturers maintain comprehensive inventory critical wear parts vibrator assemblies springs panel modules ensuring availability minimize potential extended downtime events