Wałbrzyskie Zakłady Koksownicze "Victoria" S.A. in Wałbrzych, Lower Silesia, is the world's leading producer of special foundry coke with a grain size of over 100 mm. The excellent quality of the coke strengthens the company's reputation and market position, with its products being highly valued in the global market. VICTORIA focuses on the production and sale of coke and coal by-products, including foundry coke, blast furnace coke, and industrial coke. Its by-products include tar, benzene, ammonium sulfate, and coking gas. By specializing in high-quality foundry coke, VICTORIA meets the demanding requirements of a specific customer base. Long-term export contracts and an annual production of approximately 500,000 tons of coke solidify the company's market leadership in Europe. (Source: www.wzkvictoria.pl/)
In 2010, the operator decided to replace the existing screening machines with more efficient models. The new screens were required to expand the product range, be durable and wear-resistant, offer high throughput capacity, and provide precise coke separation. They also needed to be adaptable to various coke sizes and reliable in operation to minimize downtime. It was also crucial that the supplier could provide fast support for maintenance and spare parts. A significant limitation, however, was that substantial modifications to the existing infrastructure of the sorting plant could not be implemented due to technical constraints. Additionally, production had to proceed without interruption throughout the modernization process.
IFE offered to supply linear vibrating screens with unbalanced exciters. These machines met the coking plant's requirements and ensured the acceleration of the entire vibrating mass to up to 6g (six times the acceleration due to gravity). This results in excellent screening performance while minimizing the likelihood of clogging in the coke screens. Wear-resistant rubber panels and abrasion-resistant materials (ceramic and composite armor plates) significantly extend the lifespan of the machines. The sizing of the screens was initially conducted using specialized software, supplemented by experience from previous projects. The screens were optimally integrated into the existing infrastructure and have since been operating efficiently, allowing flexibility through panel changes and different perforations to adapt to varying requirements. The conversion to IFE linear vibrating screens was carried out gradually, and a total of 23 screens were installed over the years.
The production and screening process is designed so that larger coke pieces, especially those over 80 mm, which are used in special casting and mineral wool production, can be directly loaded onto wagons and trucks. Mineral wool made from coke from the VICTORIA coking plant helps reduce heating costs as an insulation material, thereby lowering the emissions generated during the production of this heat. Coke with a smaller grain size (0-80 mm) is refined in a separate fine coke sorting plant and sold according to the specifications of the end customer. The finer fractions (20-80 mm) are supplied to steel mills and other industries.
The installation of these two screening lines remains particularly memorable. The screens had to be brought into the plant through an entrance door located 30 meters above the ground. After the IFE screens were delivered to the storage area of the coking plant, they were partially disassembled on-site. This reduced their weight and allowed the machines to fit through the limited size of the installation opening.
Herbert Teurezbacher, who was responsible for the installations on behalf of IFE, commented: "These were truly interesting operations involving disassembly and reassembly, but thanks to our many years of experience, everything went smoothly.
With the support of our Polish representative, H+J Biuro Techniczne, there were also no language barriers. Overall, the installations were a valuable experience that brought us closer together as a team."
This flexible solution makes it possible to process even small quantities quickly and precisely according to the customer's requirements. The material is also pre-sorted for transport. A high proportion of fines in the dispatch product can lead to complaints, so screening is an important quality assurance measure.
RENDERING COARSE SCREENING PLANT NEW (4 LINES)
Delivery in 2022.
IFE vibrating feeder
IFE vibrating feeder
Direct drive via cardan shaft - regulation via frequency converter
Direct drive via cardan shaft - regulation via frequency converter
IFE unbalanced exciter
IFE unbalanced exciter
Stationary cover
Stationary cover
Successful modernization
Zygmunt BURY, Head of the Investment and Development Department at the VICTORIA Coking Plant at the time of the major investments, explains: “Thanks to the transition to IFE screening machines, we were able to reduce ongoing repair and maintenance costs of the screens across all sorting plants by nearly 20 %. At the same time, we increased the efficiency and productivity of the entire production process by 4 to 5 %. The strict installation schedule was 100 % adhered to, and the services described in the offer align perfectly with the actual implementation. It has been rewarding to work with such reliable partners as IFE and h+j Biuro Techniczne.”