Màn hình rung Coke Nhà sản xuất ODM
1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT
Is your coke handling operation plagued by persistent bottlenecks, chi phí bảo trì quá mức, và chất lượng sản phẩm không đồng đều? Dành cho người quản lý nhà máy giám sát sàng lọc than cốc, common challenges directly impact the bottom line:
chói mắt & Thời gian ngừng hoạt động: Khỏe, các hạt than cốc ẩm bám vào sàn màn hình, gây mù nhanh chóng. This reduces effective screening area by up to 40%, forcing frequent shutdowns for manual cleaning and slashing throughput.
Mặc sớm & High OPEX: Bản chất mài mòn của than cốc luyện kim làm tăng tốc độ mài mòn trên tấm màn hình, bộ bài, và chất kích thích. Unplanned component replacements and associated labor can increase annual maintenance budgets by 25% hoặc hơn.
Tách tiền phạt không hiệu quả: Inadequate vibration dynamics lead to poor segregation of breeze (coke fines under 10mm). This results in product contamination, lost revenue from missized material, and potential downstream process issues.
Mệt mỏi kết cấu & Vibration Transmission: High Gforces needed for effective screening transmit damaging vibrations to the support structure and surrounding equipment, leading to cracks, foundation issues, and safety concerns.
Are you searching for a robust screening solution that delivers consistent uptime, lowers total cost of ownership, and ensures precise size separation for your coke product?
2. TỔNG QUAN SẢN PHẨM
The Coke Vibration Screen is a heavyduty industrial screening machine engineered for the highcapacity sizing and scalping of metallurgical coke in battery, quenching, and sorting stations. Its core function is to separate crushed coke into precise fractions (ví dụ., than cốc lò cao, coca hạt, gió nhẹ) while efficiently removing fines.
Quy trình hoạt động:
1. Cho ăn & Phân bổ: Crushed coke is uniformly fed onto the inlet end of the inclined screen deck via a chute or feeder.
2. Sự phân tầng & Sự tách biệt: Cường độ cao, linear or elliptical vibration stratifies the material bed. Smaller particles pass through precisely sized deck apertures; oversized particles travel across the deck surface.
3. Phóng điện: Correctly sized fractions are discharged via separate outlets—oversize to crushers for recirculation or as product, undersize as breeze or product—ensuring a clean separation.
Phạm vi ứng dụng: Primary sizing of metallurgical coke after crushing; scalping of oven discharge; dedusting and fines removal; recovery operations.
Hạn chế: Không được thiết kế cho các vật liệu dính không có công nghệ sàn chuyên dụng; maximum feed size is constrained by deck opening and machine design; requires controlled feed rate for optimal efficiency.
3. TÍNH NĂNG CỐT LÕI
Hệ thống sàn hạng nặng | Cơ sở kỹ thuật: Modular polyurethane or rubberclad steel panels with reinforced fixing | Lợi ích hoạt động: Dramatically increased service life under abrasive conditions; reduced noise levels (by ~10 dBA); panels are easily replaced in sections minimizing downtime | Tác động ROI: Cuts panel replacement costs by up to 60% over traditional woven wire decks.
AntiBlinding Technology | Cơ sở kỹ thuật: Integrated ball tray decks or ultrasonic screen mesh cleaning systems | Lợi ích hoạt động: Continuous microimpact dislodges lodged particles near aperture openings maintaining nearoriginal open area | Tác động ROI: Sustains design capacity throughput reduces cleaning downtime by over 70%.
Balanced Elliptical Vibration | Cơ sở kỹ thuật: Twin shaft exciter with outofphase synchronized weights generating an elliptical throw pattern | Lợi ích hoạt động: Optimized material travel speed with sharp stratification enhances separation accuracy especially for midrange sizes (1030mm) | Tác động ROI: Improves product purity by an average of 15% reducing recrush load and maximizing premium fraction yield.
Bụi kèm theoThiết kế chặt chẽ | Cơ sở kỹ thuật: Gasketed side plates and dust hood connections with integral skirt boards | Lợi ích hoạt động: Contains airborne coke dust at transfer points improving site air quality meeting environmental standards | Tác động ROI: Lowers housekeeping costs mitigates health safety risks avoids potential regulatory noncompliance fines.
Isolated Vibration Frame | Cơ sở kỹ thuật: Dynamic vibration isolators (rubber or spring) between the vibrating body and stationary base frame | Lợi ích hoạt động: Hấp thụ hơn 95% of dynamic forces preventing transmission to supporting structures eliminates fatigue failures | Tác động ROI: Removes need for massive dedicated foundations reduces installation time capital cost protects plant infrastructure integrity.
Centralized Greasing Lube System | Cơ sở kỹ thuật: Manifold with lines feeding all major bearing points from a single access port | Lợi ích hoạt động: Enables safe rapid lubrication during brief pauses extends bearing life under highload hightemperature conditions | Tác động ROI: Standardizes preventive maintenance intervals reduces bearing failure rates by an estimated 40%.
4. LỢI THẾ CẠNH TRANH
| Chỉ số hiệu suất | Tiêu chuẩn ngành | Giải pháp màn hình rung Coke | Lợi thế (% sự cải tiến) |
|||||
| Deck Panel Lifespan | Woven wire mesh lasts 23 tháng dưới sự mài mòn nặng nề | Polyurethaneclad modular panels last 812 tháng | +300% cuộc sống phục vụ |
| Hiệu quả sàng lọc | ~85% efficiency for midsize separation due to blinding | Duy trì >92% efficiency via antiblinding systems | +78% sustained efficiency |
| Thời gian ngừng bảo trì | 812 hours monthly for cleaning bearing checks panel replacement
| Energy Consumption per Ton ~0.12 kWh/ton processed
| Breeze (10mm) Contamination in Product Fraction
5. THÔNG SỐ KỸ THUẬT
Dung tích / Đánh giá: Mô hìnhphụ thuộc vào 200 TPH đến hơn 1500 TPH throughput capacity standard designs available
Yêu cầu về nguồn điện: Drive motor range from 7.5 kW để 45 kW depending on screen size mass excitation force
Thông số vật liệu: Highstress frame components S355JR steel side plates wear liners Hardox®400 Abrasionresistant polyurethane rubber composite deck materials
Kích thước vật lý (Mô hình điển hình): Deck Size (DàixRộng): 3m x1 .5m Overall length:~4 .2m Overall width:~2 .8m Height:~1 .6m Weight:~6500kg
Phạm vi hoạt động môi trường: Nhiệt độ môi trường xung quanh:20°C +50°C Feed material temperature upto120°C(tối đa) Weather protection IP65 enclosure optional
6. KỊCH BẢN ỨNG DỤNG
Metallurgical Coke Plant Blast Furnace Feed Preparation Challenge:: Existing screens blinded within hours due high moisture content in quenched coke causing severe bottleneck before furnace feed bins resulting in inconsistent size distribution affecting furnace efficiency
Giải pháp:: Installation two large doubledeck Coke Vibration Screens equipped ball tray antiblinding decks isolated base frames
Kết quả:: Screening availability increased from94%. Blast furnace feed consistency improved quantified as+/5mm size variation reducedby30%. Annual maintenance labor hours decreasedby1200
Coke Sorting Terminal Product Diversification Challenge:: Terminal needed produce three distinct saleable products(>50mm2550mm<25mm)from single feed stream but existing separator generated excessive fines(<10mm)in midrange fraction reducing its market value
Giải pháp:: Implementation multislope Coke Vibration Screen with precision elliptical vibration finetuning deck tensioning system
Kết quả:: Product purity each fraction achieved>95%. Revenue from midrange(2550mm)fraction increasedby18%due reduced fines content System handled variable feed rates without performance degradation
7. CÂN NHẮC THƯƠNG MẠI
Bậc định giá thiết bị: Entrylevel standard duty screens(starting~$25000);Heavyduty customengineered units($65000$200000+)based size configuration options
Tính năng tùy chọn / nâng cấp: Stainless steel construction critical areas hotmaterial handling kits spray bar systems different deck types(harps tensioned polyurethane etc.) variable frequency drives advanced condition monitoring sensors
Gói dịch vụ: Tiered annual maintenance contracts covering inspection parts discounts priority support Extended warranty available upto36months Comprehensive training programs operational maintenance staff included
Financing Options Available through partners include equipment leasing longterm rental purchase plans tailored capital expenditure cycles Project financing considered largescale installations
8. Câu hỏi thường gặp
Q1 How do we determine correct screen size deck configuration our specific capacity requirements?
Our engineering team requires your detailed feed rate particle size distribution(P80 D50)desired product splits moisture content This data allows us model recommend optimal machine specifications guarantee performance
Q2 Can this equipment integrate our existing PLC control system material handling network?
Yes standard designs include control panel compatible common industrial protocols(Profibus Ethernet/IP etc.) We provide necessary interface documentation facilitate integration your plant SCADA system
Q3 What typical installation timeline foundation requirements?
With isolated design foundation requirements less stringent than older screens Typical installation including positioning electrical mechanical connection commissioning takes510working days depending complexity Preinstallation foundation drawings issued advance
Q4 Are spare parts readily available what expected lead times?
We maintain strategic inventory critical wear parts(decks bearings exciters)at regional hubs Standard parts ship within48hours Custom components have lead times communicated upfront during purchase Longterm supply agreements ensure ongoing support
Q5 How does equipment handle variations feed rate material composition?
Robust design accommodates reasonable fluctuations Variable speed drive option allows operators adjust vibration intensity optimize performance realtime changing conditions ensuring consistent output quality