1. PAINPOINT DRIVEN OPENING

Is your coke handling operation facing persistent bottlenecks and escalating costs? For plant managers and engineering contractors, the screening phase is a critical pressure point. Common challenges include:
Excessive Downtime for Screen Deck Changes: Frequent blinding and wear from abrasive coke fines lead to costly, unplanned shutdowns, halting your entire processing line.
Inconsistent Product Gradation: Inefficient separation results in offspec coke (undersize in product or oversize in breeze), directly impacting product revenue and downstream process efficiency.
High Maintenance & Replacement Costs: The abrasive nature of coke rapidly degrades screen panels and components, driving up spare parts inventories and labor expenses.
Structural Fatigue & Vibration Transmission: Poorly isolated vibration damages support structures and creates unsafe working environments, leading to longterm capital repair costs.

Are you evaluating how to increase throughput reliability, reduce total cost of ownership, and ensure consistent product quality? The right Coke Vibration Screen is not just a machine; it’s a strategic investment in operational stability.

2. PRODUCT OVERVIEW

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the scalping, sizing, and dedusting of metallurgical coke and coke breeze in quenching towers, blast furnace feed systems, and byproduct recovery plants.

Operational Workflow:
1. Feed Introduction: Bulk coke from crushers or conveyors is evenly distributed onto the screen’s feed box.
2. Stratified Vibration: Highintensity, linear or elliptical motion stratifies the material, forcing fines downward while conveying oversize across the deck.
3. Precise Separation: Sized apertures on robust screen panels allow undersized particles (25mm breeze or other specified cuts) to pass through.
4. Discharge: Correctly sized product (e.g., +25mm blast furnace coke) discharges from the deck end, while fines are collected underneath.

Application Scope: Primary screening of hot or quenched metallurgical coke, sizing of foundry coke, removal of coke breeze from blast furnace feed. Not typically recommended for wet screening applications or extremely sticky materials without specialized modifications.

3. CORE FEATURES

HeavyDuty Deck Support System | Technical Basis: Reinforced crossmembers with abrasionresistant caps | Operational Benefit: Eliminates deck sagging and premature panel failure under high load | ROI Impact: Extends panel life by up to 40%, reducing part change frequency and downtime.

Controlled Vibration Isolation | Technical Basis: Highperformance rubber or coil spring isolators | Operational Benefit: Contains over 95% of dynamic forces, preventing transmission to the support structure | ROI Impact: Eliminates costly structural reinforcement repairs and reduces ambient vibration for operators.

AbrasionResistant Panel Technology | Technical Basis: Modular polyurethane or hardened steel panels with reinforced mounting systems | Operational Benefit: Withstands impact and abrasion from sharpedged coke while resisting blinding | ROI Impact: Lowers costperton for screen media by balancing durability with effective open area.

DualVibrator Drive System | Technical Basis: Two synchronized vibratory motors generating linear force | Operational Benefit: Provides consistent material travel speed and reliable startup under loaded conditions | ROI Impact: Ensures stable throughput targets are met with minimal maintenance compared to complex shaftdriven systems.

Enclosed Dust Management Design | Technical Basis: Integral dust sealing flanges at feed/discharge points with skirtboard compatibility | Operational Benefit: Significantly contains airborne coke dust at transfer points | ROI Impact: Reduces housekeeping labor and enhances compliance with plant environmental standards.

QuickChange Deck Tensioning System | Technical Basis: Bolted wedge or hydraulic tensioning mechanisms for panel clamping | Operational Benefit: Allows single operators to safely change screen panels in reduced time | ROI Impact: Cuts planned maintenance window duration by over 50%, increasing plant availability.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Coke Vibration Screen Solution | Documented Advantage |
| : | : | : | : |
| Panel Lifespan (Abrasive Coke) | 34 Months (Standard Steel) | 57 Months (Optimized Polyurethane/Alloy) | +60% Improvement |
| Annual Availability (Uptime %)| ~92% (Incl. Downtime for Changes)| >96% (with QuickChange Systems)| +4 Percentage Points |
| Vibrational Force Transmitted to Structure| 1520% Unisolated Force| 75% Reduction |
| Throughput Consistency (±% from target)| ±1015% Variance Under Load| Maintains within ±5% Target Feed Rate| Variance Reduced by Over 50% |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Designed for throughputs from 200 to 2,500 metric tons per hour (MTPH), depending on aperture size and material density (~0.50.7 t/m³ for coke).
Power Requirements: Driven by standard industrialgrade vibrator motors (IP66 protection), typically ranging from 2 x 7.5 kW to 2 x 30 kW per unit, based on machine size.
Material Specifications:
Deck Frame & Sideplates: ASTM A36 Steel with AR400 abrasionresistant liners at wear points.
Screen Decks: Options include modular polyurethane panels (Shore A ~90), perforated manganese steel (Hadfield Grade), or woven wire cloth.
Isolation System: Multilayered rubber buffers or steel coil springs.
Physical Dimensions: Singledeck units typically range from 1.8m wide x 4.8m long to 3.6m wide x 9m long; custom sizes available.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; handles material temperatures up to ~100°C continuously with appropriate component specifications.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feed System

Challenge A major steel producer experienced excessive structural cracking around their aging screens due to vibration transmission, coupled with weekly panel changes causing ~8 hours of lost feed time.
Solution Installation of two heavyduty linear motion Coke Vibration Screens featuring advanced coil spring isolation systems and quickchange polyurethane decks.
Results Structural vibration measurements dropped by over 80%, eliminating further damage concerns. Panel changeover time was reduced to under three hours per occurrence directly contributing to an estimated additional $150k annual production value through improved availability

Coke Battery ByProduct Processing

Challenge Inconsistent separation of breeze (12mm) from saleable foundry coke led to product quality penalties an average revenue loss of $18/ton on offspec loads
Solution Implementation of a twodeck sizing screen utilizing a top deck for scalp removal an optimized lower deck with precisely tensioned woven wire panels ensuring accurate cut points
Results Product gradation consistency improved dramatically achieving specification compliance rates exceeding . This eliminated quality penalties saving an estimated $450k annually

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers vary primarily based on size capacity construction materials

Standard Duty Tier For lowercapacity applications (1000 MTPH) includes all core features advanced isolation extended wear packages

Optional Features Include:
Stainless steel construction components for highly corrosive environments
Specialized heating systems prevent condensation blinding in cold climates
Advanced condition monitoring sensors bearing temperature vibration analysis

Service Packages Available:
1 Basic Package Standard warranty commissioning support spare parts list
2 Comprehensive Plan Includes scheduled inspections priority parts dispatch discounted labor rates

Financing Options Flexible commercial leasing structures are available allowing you preserve capital expenditure budgets These can be tailored over toyear terms

8 FAQ

Q What is the lead time for a customsized Coke Vibration Screen?
A For most standard configurations lead times range between weeks following design approval Nonstandard sizes may require additional engineering manufacturing time

Q Can your screens integrate with our existing PLC control system?
A Yes Our units can be supplied with standard motor starters but are designed for easy integration into plantwide control systems via dry contact relays We provide comprehensive IO documentation

Q How does the operational noise level compare?
A Field data shows that our fully enclosed designs combined with isolated vibrators typically operate at dB(A) measured one meter from the machine meeting common workplace regulations

Q What is the expected bearing service life under continuous operation?
A With proper sealing lubrication our vibrator bearings are rated for a minimum of operating hours under normal load conditions which translates approximately years in continuous service before planned replacement

Q Are trial tests possible before purchase?
A We can arrange testing of your specific material sample at our facility using pilotscale equipment Data on screening efficiency capacity wear rates will be provided