1. PAINPOINT DRIVEN OPENING

Is your coke handling operation compromised by inefficient screening? Common challenges with standard vibratory screens directly impact your bottom line and plant reliability.

Excessive Downtime for Screen Deck Changes: Frequent blinding and wear of screen cloths halt your entire sorting line. Each changeover can cost hours of lost production and significant labor expense.
Inconsistent Product Grading & Fines Contamination: Inadequate vibration control or poor deck design leads to offspec coke product. This results in rejected loads, customer penalties, and reduced product value.
High Maintenance Costs & Component Fatigue: Harsh, abrasive coke particles rapidly degrade underengineered screen boxes, decks, and vibrator mechanisms, leading to unplanned repairs and parts replacement.
Structural Integrity Concerns Under Load: Continuous hightonnage processing can induce stress cracks in welded frames or failures in isolation systems, creating safety risks and major capital repairs.

Are you seeking a screening solution that delivers consistent uptime, protects product quality, and reduces your total cost of ownership? The right industrialgrade Coke Vibration Screen is engineered to address these exact operational challenges.

2. PRODUCT OVERVIEW

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the highvolume sizing and scalping of metallurgical coke and similar abrasive materials in bulk handling plants. Its core function is to separate coke into precise size fractions (e.g., blast furnace coke, nut coke) while removing fines and contaminants.

Operational Workflow:
1. Feed & Distribution: Raw or processed coke is fed onto the screen’s robust feed box, which evenly distributes material across the full width of the top deck.
2. Stratification & Separation: Highintensity, linear or elliptical vibration stratifies the material bed. Smaller particles pass through apertures in the screen media (wire cloth, polyurethane panels), while larger particles travel across the deck surface.
3. Discharge & Conveyance: Correctly sized fractions are discharged via separate chutes onto designated conveyors or into storage bins for downstream processing or shipment.

Application Scope: Primary sizing of ovendischarged coke, secondary screening for blast furnace feed, recirculating load separation in crushing circuits.
Limitations: Not designed for sticky or highly moist materials without pretreatment; maximum capacity is governed by particle size distribution and deck configuration.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin panel design with independent tensioning | Operational Benefit: Operators can replace individual worn panels in under 30 minutes without dismantling adjacent sections. | ROI Impact: Reduces screen cloth downtime by up to 65% versus traditional fulldeck replacements.

HeavyDuty Vibrator Assembly | Technical Basis: Double eccentric shaft with oversized roller bearings housed in a rigid mass frame | Operational Benefit: Generates consistent, highGforce vibration unaffected by load variance; lubricatedforlife bearings eliminate daily greasing points. | ROI Impact: Field data shows a 40% increase in mean time between failures (MTBF) compared to standard vibrator units.

Frame Stress Management | Technical Basis: Finite Element Analysis (FEA) optimized side plates with reinforced cross members | Operational Benefit: Minimizes harmonic distortion and fatigue stress points under cyclical loading, preventing frame cracking. | ROI Impact: Extends structural service life by years, avoiding premature capital replacement costs.

Advanced Isolation System | Technical Basis: Multistage rubbercoil composite springs or air isolators | Operational Benefit: Absorbs over 95% of dynamic forces before they transfer to the support structure, protecting building integrity. | ROI Impact: Eliminates costly structural reinforcement needs and reduces ambient vibration affecting nearby equipment.

AbrasionResistant Lining Package | Technical Basis: Bolton wear plates made from AR400 steel at all critical impact points (feed box, discharge lips) | Operational Benefit: Protects the base frame from direct abrasion, ensuring longterm dimensional integrity of the screen body. | ROI Impact: Turns potential major frame repair into simple liner plate replacement, slashing longterm maintenance expenditure.

Dust Containment Design| Technical Basis: Integrated sealing flanges and skirt boards with durable rubber dust curtains| Operational Benefit: Significantly reduces airborne particulate emission at feed and discharge points.| ROI Impact: Lowers environmental compliance risks and reduces material loss to atmosphere.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability / Uptime | 8590% (incl. maintenance stops)| >94% target availability| +510% more production time |
| Screen Media Change Time (Full Deck) | 68 hours (welded/bolted) | 34 hours (modular system)| 50% labor & downtime |
| Bearing Service Life (Vibrator) | ~8,00010,000 hours| 14,000+ hours design life| +40% increased lifespan |
| Force Transmission to Structure| Up to 25% dynamic force transfer|<5% dynamic force transfer|80% reduction in structural stress|
| Wear Life on Critical Liners(Mild Steel)| 612 months| 2436 months (AR400 Steel)| +200300% longevity |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Sizes from 1.2m x 3m up to 2.4m x 6m; capacities from 150 TPH up to over 1,200 TPH depending on aperture size and material gradation.
Drive & Power Requirements: Dual shaft mechanical vibrator driven by twin TEFC electric motors via Vbelts; power range from 15 kW up to 55 kW per motor based on screen size.
Material Specifications: Main frame constructed from S355JR structural steel; side plates are minimum 10mm thick with additional wear liners; screen decks support tensioned wire cloth (highcarbon or stainless steel) or modular polyurethane panels.
Physical Dimensions & Weight: Varies significantly by model; e.g., a standard 1.8m x 4.5m unit has an approximate footprint of 5m L x 2.5m W x ~2m H; weight approx. ~812 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; dust protection rating standard IP65 for motors and electrical components.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feed Preparation

Challenge A major steel producer faced inconsistent blast furnace coke sizing (2575mm), with excessive fines (<10mm) causing permeability issues in the furnace burden column.
Solution Installation of a twodeck heavyduty Coke Vibration Screen with precisely calibrated wire cloth apertures for strict fraction control ahead of the furnace bins.
Results Achieved consistent product grading with <3% fines contamination; furnace efficiency improved as measured by a documented reduction in coke rate by approximately 2%.

Coke Calcining Plant – Product Classification

Challenge Postcalcination screening was causing bottlenecks due to frequent blinding of fine screens handling hot abrasive coke (~150°C), requiring weekly shutdowns.
Solution Implementation of a specialized hotduty Coke Vibration Screen featuring heatresistant isolators and tensioned stainlesssteel mesh designed for hightemperature operation.
Results Increased runtime between scheduled maintenance from one week to over six weeks; plant throughput rose by an average of 18% due to eliminated unplanned stoppages.

7.COMMERCIAL CONSIDERATIONS

Our Coke Vibration Screens are offered under a tiered pricing structure based on size/capacity:

Standard Duty Tier: For lower tonnage (<400 TPH) applications with standard features including basic liners coil spring isolation
Heavy Duty Tier (Recommended for most metallurgical applications): Includes all core features listed above AR400 liners composite spring isolation premium bearing specs
Custom Engineered Tier: For extreme capacity unique spatial constraints or specialized materials includes full CFD/FEA analysis custom isolation solutions

Optional Features include acoustic hoods explosionproof motor ratings variable frequency drives for amplitude control automated lubrication systems

Service Packages range from basic commissioning support through comprehensive multiyear maintenance agreements covering planned inspections parts supply priority technical support

Financing options are available including straight purchase capital lease or operating lease structures tailored to align with your project budgeting cycles

8.FAQ

Q What information is required ensure your Coke Vibration Screen compatible my existing layout?
A Provide detailed layout drawings current feed/discharge heights conveyor positions along required capacity(Tons/Hour) desired final fractions(mm)

Q How does this equipment impact overall plant noise levels?
A Industry testing demonstrates proper isolation combined optional acoustic enclosures can reduce operating sound pressure levels below dB(A)

Q What typical lead time delivery installation?
A Lead times vary model complexity Standard Heavy Duty models typically available within weeks Custom engineered solutions require longer engineering fabrication timeline

Q Are spare parts readily available globally?
A Yes maintain strategic inventory critical wear parts vibrator assemblies deck modules ensure expedited shipping minimize potential downtime events

Q Can existing older screens retrofitted any these features?
A In many cases yes offer retrofit kits modular deck systems upgraded isolation packages extend life improve performance legacy equipment site assessment required confirm feasibility

Q What warranty provided?
A All new Coke Vibration Screens carry comprehensive month warranty covering defects materials workmanship extended warranties available purchase

Q Do you offer performance testing before purchase?
A Yes can arrange pilotscale testing our facility provide representative sample material verify separation efficiency capacity estimates