White Label Coke Vibration Screen Assembly Plant
White Label Coke Vibration Screen Assembly Plant: Engineered for HighVolume Screening
Thử thách hoạt động: When Screen Efficiency Becomes Your Profit Margin
Đối với mọi 1,000 tons of coke processed through an inefficient screening system, you are losing an estimated 35% of saleable product to incorrect classification. In a market where metallurgical coke commands $300$450 mỗi tấn, điều đó dịch sang $9,000$22,500 in lost revenue per 1,000 tấn đã được xử lý. Add to that the cost of unscheduled downtime—averaging $2,500 ĐẾN $7,000 per hour in a midsized coking facility—and the financial case for upgrading your screening infrastructure becomes clear.
Your plant managers face a daily battle with blinding and pegging of screen media when handling abrasive, irregularly shaped coke particles. Your maintenance teams are fighting premature bearing failure and structural fatigue from highGforce vibration. Your quality control department is struggling to meet the tight size specifications (typically 1025mm, 2550mm, and 50100mm fractions) demanded by blast furnace operators and foundry customers.
The question is not whether you need a reliable coke screening solution—it is whether your current equipment is delivering the throughput, sự chính xác, and uptime your operation demands. If you are experiencing screen deck wearout in under 6 tháng, if your fines removal efficiency has dropped below 85%, or if you are manually rescreening product to meet customer specifications, you need to evaluate your screening assembly from a different angle.
Tổng quan về sản phẩm: The White Label Coke Vibration Screen Assembly Plant
This white label coke vibration screen assembly plant is a complete, turnkey screening system designed specifically for the classification of metallurgical coke, than cốc dầu mỏ, và than cốc đúc. The assembly integrates a heavyduty linear motion vibrating screen, a structural support frame, feed and discharge chutes, and a centralized lubrication system into a single, preengineered package.
The operational workflow follows a logical progression:
1. Giới thiệu nguồn cấp dữ liệu: Coke material enters the screen deck via a feed chute, with an optional impact plate to absorb the kinetic energy of falling material and protect the screen surface.
2. Sự phân tầng: The linear motion of the screen body—generated by two counterrotating vibrator motors—causes material to stratify, with smaller particles migrating to the bottom of the material bed.
3. Phân loại: Material passes over the screen deck, where particles smaller than the aperture size pass through the mesh, while oversize material travels along the deck surface toward the discharge end.
4. MultiFraction Separation: Depending on your configuration, the screen can be fitted with multiple decks to produce two, three, or four distinct product fractions simultaneously.
5. Discharge and Collection: Each fraction exits through a dedicated discharge spout, directing material to the appropriate conveyor, storage bin, or loadout point.
This assembly is engineered for continuous, highvolume operation in coke plants, nhà máy thép, and independent processing facilities. It is not designed for wet screening applications or for materials with high clay content, as these conditions can accelerate screen media wear and reduce separation efficiency.
Tính năng cốt lõi
HeavyDuty Screen Body Construction | Cơ sở kỹ thuật: Fabricated from S355JR structural steel plate with reinforced side plates and a boxtype crossmember design | Lợi ích hoạt động: Resists flexing and distortion under highvibration loads, maintaining consistent screen tension and accurate particle classification | Tác động ROI: Extends screen body service life to 10+ năm, reducing capital replacement costs by an estimated 40% compared to lighterduty frames
DualShaft Linear Motion Exciter | Cơ sở kỹ thuật: Hai đồng bộ, counterrotating eccentric shafts generate a linear vibration stroke of 812mm at 750900 vòng/phút | Lợi ích hoạt động: Cung cấp sự nhất quán, straightline throwing action that minimizes material residence time and maximizes throughput | Tác động ROI: Đạt được 1520% higher processing capacity compared to circular motion screens of equivalent deck area
Hệ thống truyền thông màn hình mô-đun | Cơ sở kỹ thuật: Polyurethane có thể hoán đổi cho nhau, cao su, or woven wire mesh panels mounted on a quickrelease tensioning system | Lợi ích hoạt động: Allows your operators to change screen media in under 2 giờ, adapting to different product specifications without replacing the entire deck | Tác động ROI: Giảm thời gian dừng chuyển đổi bằng cách 60% and lowers media inventory costs by 25% through standardization
SelfCleaning AntiBlinding Mechanism | Cơ sở kỹ thuật: Optional ball tray assembly or slotted screen media with a bouncing ball system beneath the screening surface | Lợi ích hoạt động: Continuously agitates the screen surface to dislodge nearsize particles that would otherwise block apertures | Tác động ROI: Maintains screening efficiency above 90% even with highmoisture or irregularly shaped coke, reducing rescreening costs by 30%
Enclosed Dust Containment System | Cơ sở kỹ thuật: bắt vít, gasketed covers with integrated dust collection ports connected to your existing baghouse or scrubber system | Lợi ích hoạt động: Contains airborne coke dust at the source, protecting operator health and meeting EPA and OSHA particulate emission standards | Tác động ROI: Tránh bị phạt tiền có thể xảy ra $25,000$75,000 per violation and reduces housekeeping labor by 50%
Centralized Automatic Lubrication | Cơ sở kỹ thuật: Programmable grease distribution system delivering measured lubricant to all bearings and pivot points at preset intervals | Lợi ích hoạt động: Eliminates the risk of bearing failure from underlubrication, a leading cause of unscheduled screen downtime | Tác động ROI: Kéo dài tuổi thọ sử dụng ổ trục bằng cách 200% and reduces maintenance labor hours by 34 hours per week per screen
Vibration Isolator Mounting System | Cơ sở kỹ thuật: Steel coil springs or pneumatic isolators with a natural frequency tuned to 34 times below the operating frequency | Lợi ích hoạt động: Reduces transmitted vibration to the supporting structure by up to 85%, protecting adjacent equipment and structural integrity | Tác động ROI: Eliminates the need for reinforced foundations, tiết kiệm $15,000$40,000 in civil works per installation
Lợi thế cạnh tranh
| Chỉ số hiệu suất | Tiêu chuẩn ngành | White Label Coke Vibration Screen Assembly Plant | Lợi thế (% Sự cải tiến) |
|||||
| Hiệu quả sàng lọc (loại bỏ tiền phạt) | 7585% | 9095% | 1218% cao hơn |
| Năng lực xử lý (tons/hour per m²) | 812 t/h/m² | 1418 t/h/m² | 4050% cao hơn |
| Screen Media Service Life | 36 tháng | 812 tháng | 60100% dài hơn |
| Thời gian chuyển đổi (màn hình phương tiện truyền thông) | 68 giờ | 1.52 giờ | 7075% nhanh hơn |
| Tuổi thọ dịch vụ mang | 8,00012,000 giờ | 20,00025,000 giờ | 100150% dài hơn |
| Structural Frame Weight | 1520% heavier | Optimized for strengthtoweight | 1520% lighter |
| Mức ồn tại 1 mét | 9095 dB(MỘT) | 8286 dB(MỘT) | 810 dB(MỘT) yên tĩnh hơn |
Thông số kỹ thuật
| tham số | Đặc điểm kỹ thuật |
|||
| Screen Model | WHLCVS1536 (1.5m x 3,6m) | WHLCVS1836 (1.8m x 3,6m) | WHLCVS2048 (2.0m x 4,8m) |
| Khu vực sàng lọc | 5.4 mét vuông | 6.5 mét vuông | 9.6 mét vuông |
| Số lượng sàn | 13 (có thể cấu hình) | 13 (có thể cấu hình) | 13 (có thể cấu hình) |
| Năng lực xử lý (than cốc, mật độ lớn 0.50.6 t/m³) | 80120 th | 100150 th | 150220 th |
| Biên độ rung | 812 mm (có thể điều chỉnh) | 812 mm (có thể điều chỉnh) | 812 mm (có thể điều chỉnh) |
| Tần số rung | 750900 vòng/phút | 750900 vòng/phút | 750900 vòng/phút |
| Công suất động cơ (per vibrator) | 11 kW | 15 kW | 22 kW |
| Tổng công suất lắp đặt | 2230 kW | 3037 kW | 4455 kW |
| Tùy chọn phương tiện màn hình | Polyurethane (PU), Cao su, Woven Wire Mesh | PU, Cao su, Woven Wire Mesh | PU, Cao su, Woven Wire Mesh |
| Standard Aperture Sizes | 10, 25, 50, 75, 100 mm | 10, 25, 50, 75, 100 mm | 10, 25, 50, 75, 100 mm |
| Kích thước nguồn cấp dữ liệu (tối đa) | 150 mm | 150 mm | 200 mm |
| Kích thước tổng thể (Dài x Rộng x Cao) | 4,800 x 2,400 x 2,200 mm | 4,800 x 2,700 x 2,200 mm | 6,000 x 2,900 x 2,400 mm |
| Tổng trọng lượng (bao gồm. khung) | 8,500 kg | 10,200 kg | 14,800 kg |
| Phạm vi nhiệt độ hoạt động | 20°C đến +60°C | 20°C đến +60°C | 20°C đến +60°C |
| Nguồn điện | 380V/50Hz hoặc 460V/60Hz, 3giai đoạn | 380V/50Hz hoặc 460V/60Hz, 3giai đoạn | 380V/50Hz hoặc 460V/60Hz, 3giai đoạn |
| Độ ồn (và 1m) | ≤ 85 dB(MỘT) | ≤ 85 dB(MỘT) | ≤ 86 dB(MỘT) |
Kịch bản ứng dụng
Metallurgical Coke Plant – Fines Removal Before Blast Furnace Feed
Thử thách: A steel mill in the Great Lakes region was experiencing inconsistent coke quality due to inadequate fines removal. Their existing circular motion screens were achieving only 78% removal efficiency for the 10mm fraction, resulting in blast furnace operational instability and increased coke consumption of 1520 kg mỗi tấn kim loại nóng.
Giải pháp: The plant installed a WHLCVS1836 white label coke vibration screen assembly plant with a single deck, 10mm polyurethane screen media, and an integrated dust collection hood. The linear motion design and higher Gforce (4.5G) provided better stratification and more aggressive fines removal.
Kết quả: Screening efficiency for the 10mm fraction improved to 93%, reducing coke consumption by 12 kg mỗi tấn kim loại nóng. The plant achieved annual savings of $1.8 million in coke costs, and the screen media service life extended from 4 tháng tới 9 tháng, reducing annual media replacement costs by $42,000.
Independent Coke Processing Facility – MultiFraction Classification for Foundry Market
Thử thách: A merchant coke processor in the Ohio River Valley needed to produce three distinct product fractions (1025mm, 2550mm, and 50100mm) to serve foundry and industrial customers. Their existing equipment required two separate screening passes and frequent manual intervention to maintain product specifications.
Giải pháp: The facility deployed a WHLCVS2048 white label coke vibration screen assembly plant with three decks, configured with 25mm and 50mm aperture polyurethane panels. The modular screen media system allowed for quick aperture changes when processing different coke grades.
Kết quả: The threedeck configuration produces all three fractions in a single pass, eliminating the need for rescreening. Thông lượng tăng từ 90 t/h đến 160 th, and product specification compliance improved from 92% ĐẾN 99%. The facility reduced its screeningrelated labor costs by 35% and increased saleable product yield by 4%, thêm $620,000 trong doanh thu hàng năm.
Petroleum Coke Handling Terminal – HighCapacity Screening for Export Market
Thử thách: A Gulf Coast export terminal was struggling to screen petroleum coke at the required rate of 200 t/h to meet vessel loading schedules. Their existing equipment was bottlenecking the operation, causing demurrage charges of $15,000$25,000 per vessel.
Giải pháp: The terminal installed two WHLCVS2048 white label coke vibration screen assembly plants in parallel, each handling 110120 th. The heavyduty construction and reinforced screen decks were specified to handle the abrasive, highsulfur petroleum coke without accelerated wear.
Kết quả: Combined screening capacity of 220240 t/h eliminated the bottleneck, allowing the terminal to load vessels on schedule. Demurrage charges were reduced to zero in the first year of operation. The reinforced screen decks and polyurethane media showed 30% less wear compared to previous equipment, extending service intervals and reducing maintenance costs by $85,000 hàng năm.
Cân nhắc thương mại
Bậc định giá thiết bị
| Cấu hình | Sự miêu tả | Khoảng giá (USD) |
||||
| Standard Assembly | WHLCVS1536, sàn đơn, carbon steel construction, 11động cơ kW, woven wire mesh media | $85,000 $110,000 |
| Enhanced Assembly | WHLCVS1836, sàn đôi, reinforced construction, 15động cơ kW, polyurethane media, che bụi | $130,000 $165,000 |
| HighCapacity Assembly | WHLCVS2048, ba tầng, xây dựng hạng nặng, 22động cơ kW, modular PU media, dust collection ports, central lubrication | $185,000 $240,000 |
Optional Features and AddOns
- Automated Screen Media Tension Monitoring: $8,500 $12,000 (reduces unplanned downtime from media loosening)
- Vibration Monitoring System with Remote Alerts: $6,000 $9,500 (provides early warning of bearing or structural issues)
- Custom Feed Chute with Impact Liner: $4,500 $7,000 (kéo dài tuổi thọ của phương tiện màn hình bằng cách 1520% in highimpact applications)
- Hệ thống lấy mẫu tích hợp: $3,800 $5,500 (enables automated quality control sampling)
- Sàn màn hình nóng (for highmoisture conditions): $12,000 $18,000 (maintains screening efficiency in humid environments)
- Cho thuê thiết bị: 3660 kỳ hạn tháng với $1 quyền chọn mua lại, thanh toán hàng tháng bắt đầu từ $2,400 for standard assembly
- Thanh toán trả chậm: 10% xuống, 90% đến hạn khi vận hành, allowing you to align payment with production startup
- Tài trợ dựa trên hiệu suất: Monthly payments tied to achieved throughput, reducing financial risk during rampup
- Chương trình trao đổi: Credit of 1525% of new equipment cost for your existing vibrating screen, regardless of manufacturer
Gói dịch vụ
| Bưu kiện | Bảo hiểm | Chi phí hàng năm (USD) |
||||
| Nền tảng | Kiểm tra hàng năm, bearing replacement kit, hỗ trợ qua điện thoại ưu tiên | $6,500 |
| Tiêu chuẩn | Semiannual inspection, all wear parts, 48hour onsite response, chẩn đoán từ xa | $14,000 |
| Toàn diện | Kiểm tra hàng quý, full maintenance coverage, 24hour onsite response, đảm bảo hiệu suất | $28,000 |
Tùy chọn tài chính
Câu hỏi thường gặp
Q1: Can this white label coke vibration screen assembly plant handle both metallurgical and petroleum coke?
Đúng. The screen is engineered to process both material types. Metallurgical coke, with its higher density and more uniform particle shape, is straightforward to screen. Petroleum coke, which is typically more abrasive and can have higher moisture content, requires the optional polyurethane screen media and reinforced deck construction. We recommend specifying the Enhanced or HighCapacity Assembly for petroleum coke applications to ensure adequate wear resistance.
Q2: Thời gian thực hiện điển hình từ khi đặt hàng đến khi vận hành là bao lâu?
Thời gian thực hiện tiêu chuẩn là 1012 tuần kể từ khi xác nhận đơn hàng. Điều này bao gồm 68 weeks for manufacturing, 12 weeks for quality inspection and testing, Và 23 weeks for shipping and installation. If you require expedited delivery, we offer a 6week express manufacturing option at a 12% phần thưởng, subject to production slot availability.
Q3: How does this screen assembly compare to using multiple smaller screens in parallel?
A single larger screen offers several advantages: lower capital cost per ton of capacity (tiêu biểu 1520% less), reduced footprint requirements, bảo trì đơn giản (one machine to service rather than three), and lower total power consumption. Tuy nhiên, if your operation requires redundancy to maintain production during maintenance, two smaller screens may be preferable. We can provide a sitespecific analysis to determine the optimal configuration for your facility.
Q4: What level of foundation preparation is required for installation?
The vibration isolator mounting system reduces transmitted forces to approximately 15% of the dynamic load. For most installations, a reinforced concrete pad of 300mm thickness with anchor bolts is sufficient. We provide detailed foundation drawings and installation specifications with every order. For sites with poor soil conditions or existing structures, we recommend a structural engineering review before installation.
Q5: What is the expected service life of the major components?
With proper maintenance and operation within specified parameters: screen body and structural frame, 1015 năm; vòng bi máy rung, 20,00025,000 giờ (khoảng 34 years of continuous operation); phương tiện màn hình polyurethane, 812 tháng; lưới thép dệt, 36 tháng; vibrator motors, 57 năm. These figures are based on field data from installations in coke plants and mineral processing facilities.
Q6: Can the screen be integrated with our existing control system?
Đúng. The screen assembly includes a local control panel with start/stop, giám sát rung động, and safety interlocks. For integration with your plantwide SCADA or PLC system, we offer optional Modbus TCP/IP or Profibus communication modules. Our control system is designed to interface with standard industrial protocols, and our engineers will work with your automation team to ensure seamless integration.
Q7: What training and documentation do you provide with the equipment?
Every order includes: comprehensive operation and maintenance manuals, detailed parts lists with exploded diagrams, lịch trình bôi trơn, và hướng dẫn khắc phục sự cố. We provide onsite operator and maintenance training for up to 6 personnel over 2 days at commissioning. Additional training sessions can be arranged at a cost of $1,200 mỗi ngày cộng với chi phí đi lại. We also offer annual refresher training webinars at no charge for the first year of operation.