1. PAINPOINT DRIVEN OPENING

Is your coke handling operation facing persistent bottlenecks and rising costs? The screening stage is often a critical failure point, directly impacting downstream processing and overall plant profitability. Common challenges include:

Blinding & Carryover: Moisture and fine coke particles blind screen decks, while oversized material carries over into finished product silos. This results in offspec product, customer rejections, and costly rehandling.
Excessive Downtime for Maintenance: Frequent bearing failures, screen cloth replacements, and structural weld cracks demand constant attention from your maintenance crew, stealing valuable production hours.
High Energy Consumption & Vibration Transmission: Inefficient vibratory mechanisms consume excess power and transmit destructive forces to the support structure, leading to accelerated wear on the entire screening station.
Inconsistent Grade Separation: An inability to maintain precise cut points leads to product contamination, reducing the market value of your metallurgical or foundry coke.

Are you evaluating how a purposeengineered Coke Vibration Screen can reduce your total cost of ownership, increase screening availability above 95%, and ensure consistent product quality?

2. PRODUCT OVERVIEW

A Coke Vibration Screen is a highcapacity, heavyduty screening machine designed for the scalping, sizing, and dedusting of hot or cold metallurgical coke in battery, quenching, and sorting plants. Its core function is to separate coke feedstock into precise size fractions (e.g., blast furnace coke, nut coke, breeze) while removing fines.

Operational Workflow:
1. Bulk coke from the quench car or feed conveyor is discharged onto the screen's robust feed box.
2. Highmagnitude, linear or elliptical vibratory motion stratifies the material bed and propels it across the multideck screening surfaces.
3. Undersize material passes through sequentially smaller apertures on each deck.
4. Correctly sized fractions discharge at designated outlets for conveyor transfer to storage bins or loading stations.
5. Oversize material (e.g., +80mm) exits at the screen's discharge end for potential crushing or recirculation.

Application Scope: Primary and secondary sizing of metallurgical coke, coke breeze recovery, prescreening before crushing. Not suitable for sticky materials without specialized deck technology or as a replacement for a crusher.

3. CORE FEATURES

Modular Deck System | Technical Basis: Independently tensioned polyurethane or steel wire panels | Operational Benefit: Panels can be replaced individually in under 30 minutes without dismantling adjacent decks | ROI Impact: Reduces screen cloth change downtime by up to 60%, increasing annual throughput.

Dual Counterweight Vibrator Assembly | Technical Basis: Two synchronized eccentric shafts generating a linear throwing motion | Operational Benefit: Provides consistent material travel speed and stratification regardless of feed load fluctuations | ROI Impact: Improves screening efficiency by 1520%, minimizing product contamination.

HuckBolted® Frame Construction | Technical Basis: Highstrength lock bolts applied with uniform tensile preload | Operational Benefit: Eliminates frame weld fatigue failures common in bolted/riveted designs; withstands thermal expansion from hot coke | ROI Impact: Extends structural service life by an estimated 35 years, reducing major rebuild costs.

Labyrinth & Grease Purge Sealing System | Technical Basis: Multistage seals with regulated grease pressure barrier | Operational Benefit: Excludes fine abrasive coke dust from vibrator bearing housings under all conditions | ROI Impact: Increases bearing service intervals to over 12,000 hours, cutting lubrication costs by 30%.

Coil Spring & Rubber Buffer Isolation | Technical Basis: Progressiverate steel springs with rubber dampers on all support points | Operational Benefit: Absorbs up to 95% of dynamic forces, preventing transmission to the supporting structure | ROI Impact: Eliminates costly structural reinforcement repairs and reduces surrounding equipment vibration damage.

Hot Coke Design Package | Technical Basis: Heatresistant seals, spaced deck frames for air flow, and hightemperature paint system | Operational Benefit: Allows reliable operation with coke temperatures up to 200°C postquenching | ROI Impact: Enables direct screening after quenching without cooling conveyors, streamlining plant layout.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Screening Efficiency (Grade Purity) | ~85% 90% efficiency on moist fines| >95% efficiency maintained via adjustable stroke/frequency| +5% to +10% |
| Annual Availability (Uptime) | ~88% 92%, factoring cloth changes & repairs| >96%, supported by modular decks & sealed vibrators| +4% to +8% |
| Energy Consumption per Ton Screened| Baseline (100%) reference| Approximately 85% of baseline via optimized mass balance| Reduction of ~15% |
| Bearing MTBF (Mean Time Between Failure)| ~8,000 operating hours| >12,000 operating hours with advanced sealing| Increase of ~50% |
| Total Cost of Ownership (5Year Period)| Baseline cost inclusive of parts/labor/downtime| Estimated 2025% lower based on durability & efficiency gains| Reduction of ~2025% |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Sizers from 1.2m x 3.0m to 2.4m x 6.0m; capacities from 150 TPH to over 1,200 TPH of bulk coke.
Drive & Power Requirements: Dual shaft vibrator driven by twin TEFC electric motors via Vbelts. Motor power range: 2 x 7.5 kW to 2 x 45 kW (400V/50Hz or as specified).
Deck Configuration: Up to four decks standard; customizable slope angles (15° 25°).
Screen Media Options: Tensioned polyurethane panels (for abrasion resistance), rubberclad panels (for noise reduction), or heavyduty woven wire cloth.
Construction Materials: Main frame carbon steel ST37; Side plates wearresistant steel AR235/400; Deck support frames galvanized steel.
Physical Dimensions: Varies significantly by model; largest models require ~10m L x 4m W x 3m H footprint at operating angle.
Environmental Operating Range: Ambient temperature from 20°C to +50°C; capable of handling material temperatures up to +200°C with Hot Coke Package.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feed Preparation

Challenge A major steel producer faced inconsistent blast furnace feed quality due to excessive fines (<10mm) in their +25mm furnace coke fraction from existing screens.
Solution Installation of a primaryduty linear motion Coke Vibration Screen with two decks (40mm top deck aperture /25mm bottom deck aperture) postquenching tower.
Results Screening efficiency for the +25mm fraction increased from an estimated 96%. Fines carryover reduced by over90%. This contributed directly observed reductions in blast furnace specific fuel rate within expected parameters.

Merchant Coke Producer – Product Portfolio Expansion

Challenge A merchant cokery could not efficiently produce a highvalue "Nut Coke" fraction(1530mm) due limitations their aging rotary screens creating excessive degradation
Solution A dedicated sizing circuit featuring two parallel elliptical motion Coke Vibration Screens configured one scalp oversize one precisely split nutcoke fraction
Results Plant achieved clean separation nutcoke grade allowing entry premium market segment Overall plant yield increased approximately3through recovery previously lost midsize material

7.COMMERCIAL CONSIDERATIONS

Pricing for industrialgrade Coke Vibration Screens is determined by size capacity construction specifications Standard models typically fall into three tiers:

• Tier I Standard Duty(up500TPH): For lower capacity plants cooler temperatures Includes core features modular decks sealed vibrators
• Tier II High Capacity Duty(5001000TPH): Reinforced frames highperformance vibrators mandatory hotcoke package options
• Tier III Heavy Duty Custom(1000TPH+): Engineered specific applications may include special alloys automated tensioning systems

Optional Features Include:
• Variable frequency drive(VFD)for online stroke/speed adjustment • Dust encapsulation hoods • Automated lubrication systems • Advanced condition monitoring sensors

Service Packages Available:
• Commissioning supervision • Planned maintenance agreements • Onsite inventory consignment kits critical spare parts

Financing Options:
Capital expenditure can be structured through equipment leasing programs or project financing terms typically ranging3660months subject credit approval

8.FAQ

Q What information needed ensure your screen compatible our existing layout?
A Provide basic dimensional footprint current machine along feed discharge heights connection points Flowrate desired fractions essential We will provide detailed GA drawing review

Q How does screen handle fluctuations feed rate common surge from quench cars?
A The dual counterweight design maintains consistent throwing force across wide range loads Material travel speed remains stable preventing flooding during surges ensuring separation quality

Q What typical installation timeline involve?
A For direct replacement foundation preparation followed mechanical erection electrical connection alignment Field commissioning usually requires35 working days experienced crew

Q Are performance guarantees offered?
A Yes We guarantee mechanical performance uptime based agreed specifications offer throughput efficiency warranties supported field data similar installations

Q Can retrofit existing screen structure new vibrating assembly?
A In many cases yes Our engineering team assess feasibility retrofitting modernized vibrator units older structures potentially offering significant cost saving versus complete replacement

Q What lead time expected new unit?
A Lead times vary model complexity Standard configurations typically available within1216 weeks Custom engineered solutions may require1824 weeks planning

Q What key operational checks maximize screen lifespan?
A Daily visual inspections bolt tightness monthly checks spring condition quarterly vibration analysis readings Annual comprehensive inspection bearings media recommended