1. PAINPOINT DRIVEN OPENING

Is your coke handling operation struggling with inconsistent product quality, excessive fines generation, and unplanned maintenance costs? Inefficient screening directly impacts your bottom line through:

Product Rejection: Offspec coke with excessive fines leads to customer penalties and revenue loss.
Downstream Damage: Unscreened oversize material causes costly wear and blockages in crushers and conveyors.
High Operational Costs: Frequent screen cloth changes, excessive vibration transmission damaging support structures, and high energy consumption per ton screened.
Capacity Bottlenecks: Inadequate screening efficiency creates backlogs, limiting overall plant throughput.

Are you seeking a screening solution that delivers precise grading, withstands abrasive coke materials, and operates with minimal lifecycle cost? The answer lies in a purposeengineered Bespoke Coke Vibration Screen.

2. PRODUCT OVERVIEW

A Bespoke Coke Vibration Screen is a heavyduty industrial screening machine engineered specifically for the dry separation of metallurgical coke. Unlike generic screens, it is customconfigured to match your specific feedstock granulometry, capacity requirements, and plant layout.

Operational Workflow:
1. Controlled Feed: Coke is evenly distributed across the full width of the screen’s inlet via an integrated feed box.
2. Precise Stratification: HighGforce linear or elliptical vibration stratifies material, forcing nearsize particles to contact the deck surface.
3. Efficient Separation: Sized particles pass through precisely tensioned screen panels; oversize material conveys to discharge.
4. Clean Discharge: Separated fractions are discharged into distinct chutes for downstream processing.

Application Scope: Primary sizing (scalping) and final grading of metallurgical coke (blast furnace coke, nut coke). Suitable for replacement of undersized or failing screens in existing circuits.

Limitations: Not designed for wet screening or sticky materials. Performance is contingent on correct feed rate and moisture content as per design parameters.

3. CORE FEATURES

Modular Deck System | Technical Basis: Independently tensioned polyurethane or steel wire panel sections | Operational Benefit: Panels can be replaced individually in under 30 minutes without dismantling adjacent decks | ROI Impact: Reduces maintenance downtime by up to 70% compared to boltedpanel systems.

DualMass Vibrator System | Technical Basis: Two counterrotating eccentric masses generating a linear force | Operational Benefit: Isolates dynamic forces from the support structure; only 510% of vibration is transmitted | ROI Impact: Eliminates costly structural reinforcement and reduces fatigue failures on building steelwork.

HeavyDuty Coil Spring Isolation | Technical Basis: Highcycle fatiguerated steel coil springs | Operational Benefit: Consistent vibration amplitude under fluctuating load conditions, ensuring stable screening efficiency | ROI Impact: Protects capital investment in the vibrator assembly, extending mechanical life beyond 60,000 hours.

AbrasionResistant Lining Package | Technical Basis: Wear plates (AR400/500) at feed points and sidewalls | Operational Benefit: Directs abrasive wear to replaceable liners instead of the main screen body | ROI Impact: Increases structural longevity by years, avoiding complete screen body replacement.

PLCIntegrated Condition Monitoring | Technical Basis: Vibration sensors and temperature probes on bearings | Operational Benefit: Provides realtime data on vibrator health and alerts for predictive maintenance scheduling | ROI Impact: Prevents catastrophic bearing failure, avoiding unscheduled stoppages exceeding $50k in lost production.

Variable Frequency Drive (VFD) Control | Technical Basis: AC motor with variable speed/frequency output | Operational Benefit: Operators can finetune vibration amplitude and frequency to match realtime feed characteristics | ROI Impact: Optimizes efficiency for varying feed grades; can reduce energy consumption by up to 15% during lower throughput periods.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Bespoke Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (Grade Accuracy) | 8892% on nearsize separation | Consistent 9598% efficiency across design range| +6% to +10% |
| Screen Cloth Change Time (Full Deck) | 812 hours with multiple personnel| <4 hours using modular tensioning system| 60% downtime |
| Structural Vibration Transmission (RMS Velocity)| High transmission requiring dampening pads| 80% reduction |
| Bearing Service Life (L10 Rating) @ Max Load| ~20,000 hours typical life expectancy| >60,000 hours with forced lubrication & housing design| +200% lifespan|
| Energy Consumption (kWh/Ton)| Baseline = 100% energy use per ton processed| Optimized mass/force balance reduces draw by ~15%|15% operating cost|

5. TECHNICAL SPECIFICATIONS

Capacity Range: Configurable from 200 TPH to over 2,500 TPH depending on model size and deck configuration.
Power Requirements: Drive motor from 15 kW to 75 kW; standard supply at 400/690V AC, 50/60 Hz.
Material Specifications: Main frame – carbon steel (S355JR); Contact surfaces – lined with replaceable AR400/500 steel; Screen decks – hightensile steel frame supporting modular panels.
Physical Dimensions (Example Model): Widths from 1.5m to 3.5m; Lengths from 4.5m to 8m; Installation height varies by incline angle (1525 degrees).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dustproofing standard for IP65 rating on electrical components.

6. APPLICATION SCENARIOS

[Blast Furnace Coke Plant] Challenge: An aging screen line caused frequent plugging of deck panels with wet fines (<10mm), reducing throughput by an average of 20%. Manual cleaning was hazardous and slow.

[Nut Coke Producer] Challenge: The existing screen generated excessive secondary breakage (~8% additional fines), degrading product value. Noise levels exceeded local regulations at the source.

[Solution]: Implementation of a Bespoke Coke Vibration Screen with heated deck panels and highGforce linear stroke. The system prevented moisture adhesion through controlled thermal input.

[Solution]: Implementation of a Bespoke Coke Vibration Screen featuring rubber bufferisolated side plates and a tuned elliptical motion. This gentler handling reduced particleonparticle impact breakage.

[Results]: Throughput restored to design capacity of 1,800 TPH sustained. Fines carryover reduced by over half. Deck blinding incidents eliminated entirely.

[Results]: Fines generation reduced from ~8% down below target level. Noise emissions at operator stations were reduced by over decibels through isolation engineering.

7. COMMERCIAL CONSIDERATIONS

Equipment pricing for a Bespoke Coke Vibration Screen is projectspecific but typically falls into three tiers:

1. Standard Configuration Tier ($80k $150k): Includes base frame, dualmass vibrator, standard duty liners, coil spring isolation,and basic motor starter.For defined applications with stable feed conditions.
2 .Enhanced Performance Tier ($150k $300k): Includes all Standard features plus modular polyurethane deck system,VFD control,wired condition monitoring sensors,and heavyduty abrasion liners.Recommended for hightonnage,critical sizing applications
3 .Full Plant Integration Tier ($300k+): A turnkey package including custom feed/discharge chutes,sound attenuation enclosures,factoryinstalled PLC with HMI,and advanced predictive maintenance software.Fully integrated into new or upgraded circuits

Optional features include explosionproofing,dust covers,and specialized screen media types.Service packages range from annual inspections(12%)to comprehensive multiyear coverage including parts/labor(18%).Financing options including equipment leasing are available

FAQ

What level of customization is possible?
Every unit is engineered based on your specific data including particle size distribution desired cut points available footprint current bottlenecks We adjust dimensions stroke speed deck configuration media type accordingly

How does this equipment integrate into our existing circuit?
Our engineering team conducts a layout review using your drawings We design compatible chute work interfaces ensure proper headroom access Our screens use standard mounting configurations minimizing civil work required

What is the expected operational lifespan?
With proper maintenance critical components like the main frame are designed for years The vibrator assembly has an L bearing life exceeding years Field data shows well maintained units operating reliably beyond years

Can you guarantee performance metrics like efficiency capacity?
Yes we provide performance guarantees based on agreed upon test protocols using representative samples These are formalized within our commercial proposal subject terms conditions

What does delivery installation timeline look like?
From order placement typical delivery weeks ex works Installation commissioning supervised our engineers requires additional week depending complexity Site preparation foundation work should completed prior arrival