1. PAINPOINT DRIVEN OPENING

Is your coke handling operation losing profitability to persistent screening inefficiencies? For plant managers and engineering contractors, the wrong vibration screen can be a continuous source of cost and disruption. Common challenges include:

Blinding & Carryover: Moisture and fine coke particles clog screen decks, reducing effective screening area and allowing undersize material to carry over. This contaminates product grades and forces manual cleaning, halting production.
Premature Wear & Downtime: The abrasive nature of metallurgical coke accelerates wear on screen panels, decks, and exciters. Frequent component replacement leads to unplanned downtime and high maintenance costs.
Inconsistent Sizing & Product Quality: Inadequate vibration dynamics or poor deck design result in inconsistent particle separation. This fails to meet strict customer specifications for blast furnace or foundry coke, risking contract penalties.
Structural Fatigue & Failure: Highcycle loading from continuous operation can lead to cracks in the screen body or support structure, causing catastrophic failure and extended, costly repairs.

Are you facing escalating maintenance budgets, unpredictable availability, and compromised product quality from your current screening solution? It’s time to evaluate a purposeengineered alternative.

2. PRODUCT OVERVIEW

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the highvolume separation and classification of metallurgical coke. Its core function is to efficiently sort crushed coke into precise size fractions (e.g., nut coke, breeze) while removing fines and contaminants.

Operational Workflow:
1. Feed & Distribution: Crushed coke is fed onto the screen’s robust feed box, which evenly distributes material across the full width of the primary deck.
2. Stratification & Separation: Highintensity vibration stratifies the material bed. Smaller particles pass through deck apertures, while larger particles travel across the deck surface.
3. Sizing & Discharge: Multideck configurations allow for simultaneous separation into multiple product streams (e.g., oversize, product grade(s), undersize/fines), each discharged via dedicated chutes.

Application Scope: Primary sizing of blast furnace coke, nut coke separation, recrushing circuit checkscreening, and removal of coke breeze from foundry coke.
Limitations: Not suitable for sticky materials without specialized deck technology; performance is dependent on proper feed rate and moisture content management.

3. CORE FEATURES

HeavyDuty Box Frame Construction | Technical Basis: Full continuous welding with internal crossbracing | Operational Benefit: Eliminates stress points and frame cracking under high cyclic loads | ROI Impact: Reduces risk of catastrophic structural failure, extending operational life by years and avoiding major capital repair costs.

Modular Polyurethane Deck Panels | Technical Basis: Abrasionresistant PU with tailored aperture design | Operational Benefit: Dramatically increases wear life over steel panels; reduced blinding due to material elasticity | ROI Impact: Lowers panel replacement frequency by 300400%, cutting parts inventory and labor downtime.

Dual CounterRotating Exciters | Technical Basis: Two synchronized eccentric shafts generating a linear throwing motion | Operational Benefit: Provides consistent, controllable material travel speed and stratification efficiency across entire deck width | ROI Impact: Ensures stable product sizing accuracy (+/ 2%), reducing product giveaway and quality rejections.

DustEncapsulated Bearing Assembly | Technical Basis: Labyrinth seals with grease purge ports in a rugged housing | Operational Benefit: Protects critical bearings from pervasive coke dust ingress | ROI Impact: Extends bearing service life by over 60%, preventing unplanned stops due to bearing seizure.

QuickRelease Deck Tensioning System | Technical Basis: Bolted clamp rails with standardized tool access | Operational Benefit: Enables single operator panel changeout in under half the time of traditional systems | ROI Impact: Turns a 46 hour maintenance task into a 2hour task, increasing plant availability.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Panel Service Life (Abrasive Wear) | Standard Hardened Steel Panels (36 months) | Modular Polyurethane Panels (1218 months) | +300% lifespan |
| Annual BearingRelated Stoppages| 23 events per year (824 hrs downtime)| <1 event per year (60% reduction |
| Screening Efficiency (Grade Purity) | ~8892% consistency in target fraction| 9598% consistency in target fraction| ~57% improvement |
| Structural Integrity (Mean Time Between Failure) | Major frame weld inspection/repair every 35 years| Major frame weld inspection/repair every 8+ years| +100% durability |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Modeldependent; standard range from 200 to 1,500 metric tons per hour.
Screen Decks: Single, double, or tripledeck configurations.
Deck Area: From 6 sqm to over 24 sqm.
Drive Unit: Dual shaft exciter with Vbelt drive from standard TEFC industrial motor.
Power Requirements: Motor ratings from 15 kW to 55 kW (400V/50Hz or as specified).
Vibration Amplitude & Frequency: Adjustable; typically 46 mm amplitude at 9001000 RPM.
Material Specifications: Main frame S355JR carbon steel; Side plates AR400 abrasionresistant steel; Deck support system hotdip galvanized steel.
Physical Dimensions (Example): For a model with 12 sqm deck area – Length: ~6.5m, Width: ~3.2m, Height: ~2.8m (excluding feed/discharge chutes).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dusttight construction for IP65 equivalent environments.

6. APPLICATION SCENARIOS

[Integrated Steel Mill] Challenge: A major mill’s blast furnace nut coke circuit experienced rapid blinding of wire mesh screens due to residual moisture, requiring biweekly shutdowns for cleaning. Product contamination was affecting furnace burden consistency.

[Solution]: Implementation of a tripledeck Coke Vibration Screen fitted with nonblinding polyurethane panels on the upper decks for scalping and fine stainlesssteel wire on the bottom deck for precise separation.

[Results]: Screen availability increased from 98%. Manual cleaning intervals extended from two weeks to three months. Product grade purity improved by 6%, contributing to more stable furnace operation.

[Coke Production Plant] Challenge: A merchant coke producer faced excessive carryover of fines into their premium foundry coke product line due to an undersized screen with poor dynamics.

[Solution]: Installation of a highcapacity dualdeck Coke Vibration Screen with optimized throw angle and stroke length for their specific particle size distribution.

[Results]: Fines content in the final product was reduced from an unacceptable 8% to below the required specification of <3%. This eliminated customer complaints and allowed entry into highervalue market segments.

7. COMMERCIAL CONSIDERATIONS

Our private label manufacturing program provides tailored solutions:

Pricing Tiers: Based on capacity rating (+/500 TPH), number of decks (single vs multi), drive configuration (standard vs variable frequency), level of corrosion protection (standard paint vs specialized coating systems).
Note: A customengineered Coke Vibration Screen represents a significant capital investment focused on longterm operational cost reduction.
Optional Features: Rubber buffer isolators for reduced structural loadings; stainless steel discharge hoods; spray bar systems for dedicated applications; advanced condition monitoring sensors on bearings.
Service Packages: Extended warranty plans are available alongside commissioning supervision services offered by our engineering partners globally.
Note: We strongly recommend partnering with local service engineers familiar with heavy vibrating equipment for installation oversight.
(For OEM/Resellers): Financing Options: We work exclusively B2B with equipment resellers/OEMs who may offer their own financing or leasing structures directly through their commercial channels.

8.FAQ

Q1: Is this Coke Vibration Screen compatible with our existing feed conveyor discharge height?
A1: Our designs are highly customizable regarding inlet height dimensions as part of our private label program during engineering review stage prior manufacturing commitment ensuring fit within your existing layout constraints without requiring expensive structural modifications

Q2 What impact will installing this have on our plant's structural supports?
A2 Field data shows that incorporating rubber shear spring isolators significantly reduces dynamic forces transmitted into supporting structures often by upto70%. We provide detailed load data static dynamic forces necessary for your civil engineering team verify adequacy existing supports

Q3 How does pricing compare against sourcing commodity screens from generalist manufacturers?
A3 Initial investment may be higher reflecting use premium materials heavyduty construction however total cost ownership analysis consistently shows lower lifetime cost due reduced maintenance parts consumption increased uptime improved product yield leading faster payback period typically within18–24 months depending operational intensity

Q4 What are lead times typical private label order?
A4 Lead times vary based complexity customization current production schedule Standard configured models typically available within10–14 weeks upon order confirmation approval final drawings Fully customized solutions may require16–20 weeks

Q5 Can you supply matching peripheral equipment like chutes conveyors?
A5 As private label manufacturer we focus core screening equipment supply However we can provide detailed interface drawings specifications facilitate seamless integration components sourced locally through your preferred partners reducing shipping costs logistical complexity

Q6 What documentation provided support maintenance operations?
A6 Each unit ships comprehensive documentation package including foundation drawings assembly manuals parts lists exploded diagrams lubrication schedules critical spares recommendations ensure your maintenance team has all necessary information perform effective preventative corrective maintenance

(This content is engineered as technical marketing material based on industrystandard performance data related to vibrating screens used in abrasive applications like coke handling.)