Subject: Addressing Screening Inefficiencies in Coke Processing: Precision Separation for Plant Managers & Engineering Contractors

1. PAINPOINT DRIVEN OPENING

In coke processing operations, three persistent challenges directly impact your bottom line: blinding and pegging of screen decks, which can reduce effective screening area by 3040% and increase recirculation loads; abrasive wear on contact surfaces, leading to unscheduled downtime costing $5,000$15,000 per hour in lost production; and fines carryover into the product stream, resulting in rejected loads or penalties from steel mill customers. Are your current screens failing to maintain consistent cutpoint accuracy below 6mm? Are you replacing screen panels every 23 weeks due to coke’s high abrasion index? The solution requires a machine engineered specifically for the material’s lowmoisture, highabrasion, and irregular particle shape characteristics.

2. PRODUCT OVERVIEW

The Coke Vibration Screen is a heavyduty, linearmotion vibratory classifier designed for dry sizing of metallurgical coke, petroleum coke, and foundry coke. It operates on the principle of controlled acceleration to stratify and separate material by particle size without degrading the fragile coke structure.

Operational Workflow:
1. Feed Distribution: Material enters via a flared feed box with a replaceable wear liner, ensuring even distribution across the full deck width to prevent localized overloading.
2. Stratification & Conveyance: A dualshaft vibrator assembly generates a linear stroke (812mm amplitude) at 8001000 RPM, conveying material forward while smaller particles migrate to the bottom of the bed.
3. Size Separation: Material passes over a multideck configuration (typically 23 decks). The top deck removes oversize (+50mm), the middle deck handles intermediate sizes (2050mm), and the bottom deck separates fines (6mm or 10mm).
4. Discharge: Three distinct product streams exit via dedicated chutes: oversize, midsize product, and fines reject.

Application Scope: Ideal for dry screening of coke with moisture content below 8%. Limitations: Not suitable for sticky or highmoisture (above 12%) feed without heated deck options; not designed for wet screening applications.

3. CORE FEATURES

HighGForce Linear Motion | Technical Basis: Dual counterrotating vibrator shafts with synchronized gears | Operational Benefit: Provides a consistent 5.56.5 Gforce, ensuring material stratifies rapidly and pegging is minimized | ROI Impact: Reduces screen panel replacement frequency by 40% compared to circular motion screens

AbrasionResistant Deck Construction | Technical Basis: AR400/AR500 steel plate with 1215mm thickness on impact zones; polyurethane or ceramictile screen media | Operational Benefit: Extends service life in highwear areas to 68 months versus 46 weeks for standard mild steel | ROI Impact: Direct reduction in maintenance labor costs and spare parts inventory by 35%

AntiBlinding Screen Media | Technical Basis: Selfcleaning polyurethane panels with tapered apertures or pianowire tensioned mesh | Operational Benefit: Maintains 95% open area efficiency even with nearsize particles, reducing recirculation load | ROI Impact: Increases effective throughput by 1520% without requiring a larger machine

Modular Deck Design | Technical Basis: Bolted, nonwelded deck frames with quickrelease tensioning rails | Operational Benefit: Allows singleperson screen media change in under 2 hours, compared to 68 hours for welded designs | ROI Impact: Reduces planned maintenance downtime by 60%

Sealed Vibrator Assembly | Technical Basis: Oillubricated, labyrinthsealed bearings with temperature monitoring ports | Operational Benefit: Prevents coke dust ingress, extending bearing life to 25,000+ operating hours | ROI Impact: Eliminates unplanned bearing failures, saving $8,000$12,000 per incident in repair costs

Variable Stroke Adjustment | Technical Basis: Adjustable eccentric weights on vibrator shafts | Operational Benefit: Allows finetuning of material travel speed (1525 m/min) for different coke grades | ROI Impact: Optimizes retention time for specific cut points, improving separation efficiency by 58%

Integrated Dust Containment | Technical Basis: Bolton skirt boards with rubber sealing strips at all transfer points | Operational Benefit: Reduces fugitive dust emissions by 90% at the screen interface | ROI Impact: Helps meet OSHA PEL limits for respirable coke dust without additional ventilation costs

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Circular Motion) | Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Screening Efficiency (at 6mm) | 7580% | 9295% | +1520% |
| Panel Life (Polyurethane) | 812 weeks | 2432 weeks | +100150% |
| Mean Time Between Failures | 1,500 hours | 4,000 hours | +166% |
| Noise Level (at 1 meter) | 95100 dB(A) | 8287 dB(A) | 13% |
| Power Consumption per Ton | 0.81.2 kWh/t | 0.50.7 kWh/t | 3040% |
| Changeover Time (1 deck) | 68 hours | 1.52 hours | 75% |

5. TECHNICAL SPECIFICATIONS

| Parameter | Specification |
| : | : |
| Model Range | CSV1224 (1.2m x 2.4m) to CSV2448 (2.4m x 4.8m) |
| Capacity Range | 50 TPH to 350 TPH (depending on cut point and deck area) |
| Cut Point Range | 3mm to 80mm (adjustable via screen media selection) |
| Power Requirement | 2 x 7.5 kW to 2 x 30 kW (dual vibrator motors) |
| Voltage | 460V / 3phase / 60Hz (standard); 380V / 50Hz (available) |
| Material of Construction | AR400 steel (main frame); 304SS (feed box liners) |
| Screen Media | Polyurethane (standard); Tensioned wire mesh (optional); Ceramic tiles (highwear zones) |
| Operating Temperature Range | 20°C to +80°C (ambient); material temperature up to 120°C |
| Vibration Amplitude | 812 mm (adjustable) |
| Vibration Frequency | 8001000 RPM |
| Total Weight (CSV1848) | 8,500 kg (18,700 lbs) |

6. APPLICATION SCENARIOS

Metallurgical Coke Plant – Primary Sizing | Challenge: A steel mill’s coke plant was experiencing 12% fines carryover (+6mm) into the blast furnace feed, causing inconsistent permeability and increased coke rate. The existing screens were blinding every 4 hours. | Solution: Installed a CSV2448 Coke Vibration Screen with 6mm polyurethane panels and a 10mm stroke. | Results: Fines carryover reduced to 2.5%. Screen panel life increased from 3 weeks to 7 months. Blast furnace coke rate decreased by 8 kg/THM, saving $1.2M annually in coke costs.

Petroleum Coke Calcining – Product Recovery | Challenge: A calciner facility was losing 8% of product (4mm) to the reject stream due to poor fines recovery on existing screens. | Solution: Deployed a CSV1836 with 4mm slotted polyurethane media and reduced stroke to 8mm for longer retention time. | Results: Product recovery increased by 6.5%, adding 4,500 tons of saleable product per year. Payback period was 4 months.

Foundry Coke – Quality Control | Challenge: A foundry required strict 20mm +10mm product specification. Current screens produced 18% oversize and 10% undersize. | Solution: Implemented a twodeck CSV1224 with 20mm top deck and 10mm bottom deck, using selfcleaning rubber panels. | Results: Product specification compliance improved to 98%. Customer rejections dropped from 5% to 0.2%.

7. COMMERCIAL CONSIDERATIONS

Equipment Pricing Tiers (FOB, excluding installation):

• Standard Package (CSV1224): $45,000 $65,000 (includes base machine, standard polyurethane panels, and 2year warranty)
• Enhanced Package (CSV1836): $85,000 $120,000 (includes AR500 liners, ceramic tile impact zones, and 3year extended warranty)
• Premium Package (CSV2448): $150,000 $210,000 (includes all enhanced features plus variable frequency drive, remote monitoring sensors, and 5year structural warranty)



Optional Features:

• Heated deck system for highmoisture coke (+$12,000)
• Dust collection hood with integrated ductwork (+$8,500)
• Wireless vibration monitoring system (+$4,200)
• Spare parts kit (1 set of panels, bearings, seals) (+$6,500)

Service Packages:

• Basic: Commissioning and operator training (2 days) – $4,500
• Standard: Quarterly inspection and wear analysis – $12,000/year
• Comprehensive: Full maintenance contract including all wear parts – $28,000/year

Financing Options:

• Net 30 terms for qualified buyers
• 12month leasetoown at 4.5% APR
• 36month equipment financing at 6.9% APR (subject to credit approval)

8. FAQ

Q: Can this screen handle coke with moisture content above 10%?
A: Standard models are designed for dry screening (<8% moisture). For higher moisture, we recommend the heated deck option or a predrying step. Operating above 12% moisture without modifications will cause rapid blinding.

Q: What is the typical lead time for a custom Coke Vibration Screen?
A: Standard models ship in 810 weeks. Custom configurations (nonstandard widths, special media) require 1216 weeks. We maintain a stock of common wear parts for immediate shipment.

Q: How does this screen compare to a grizzly feeder for primary coke sizing?
A: A grizzly is suitable for scalping +100mm material but provides poor efficiency below 25mm. The Coke Vibration Screen achieves 9295% efficiency at cut points as low as 3mm, making it the correct choice for final sizing and fines removal.

Q: What maintenance training do you provide for plant operators?
A: Our commissioning package includes a 2day onsite training covering daily inspection points (bearing temperature, stroke alignment, tension), screen media change procedures, and troubleshooting common issues like material surging.

Q: Can this machine be retrofitted into an existing screening tower?
A: Yes. We provide a dimensional drawing with mounting points and dynamic load calculations. The linear motion design typically requires less structural reinforcement than circular motion screens of equivalent capacity.

Q: What is the expected lifespan of the vibrator assembly?
A: With proper lubrication (oil changes every 500 hours) and seal maintenance, the vibrator assembly operates reliably for 25,00030,000 hours before requiring bearing replacement. The gearbox housing is designed for rebuild.

Q: Do you offer performance guarantees for specific cut points?
A: Yes. We guarantee a minimum screening efficiency of 90% at the specified cut point for your material, provided feed conditions (moisture, size distribution) remain within the agreed parameters. This is validated during commissioning.