1. PAINPOINT DRIVEN OPENING

Are you managing escalating costs and unpredictable downtime in your coke handling and classification process? Inefficient screening directly impacts your bottom line through lost production, excessive recrushing of onspec material, and premature wear on downstream equipment. Consider these common operational challenges:
Blinding & Carryover: Moisture and fine coke particles blind screen decks, reducing effective screening area and forcing oversized material into the product stream, compromising quality.
Excessive Maintenance Downtime: Conventional screens with highvibration components suffer frequent bearing failures, deck cloth damage, and structural fatigue, leading to unplanned shutdowns.
Low Screening Efficiency: Inconsistent material flow and poor stratification result in a high percentage of misplaced particles, wasting energy in reprocessing and failing to meet strict size specifications for blast furnace or foundry coke.
High Operational Costs: The combined effect of frequent part replacements, high energy consumption per ton processed, and laborintensive cleaning protocols erodes profit margins.

Is your current screening solution contributing to these issues? A purposeengineered Coke Vibration Screen is not merely a piece of equipment; it is a critical process control point designed to resolve these specific challenges.

2. PRODUCT OVERVIEW

The HeavyDuty Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the precise size separation of metallurgical coke (met coke) and petroleum coke (pet coke). It is built to handle abrasive materials while resisting the clogging effects of residual moisture and fines.

Operational Workflow:
1. Controlled Feed: Sized coke from crushers is evenly distributed across the full width of the screen's feed box.
2. Stratification & Separation: The dualvibrator generated linear motion rapidly stratifies material, forcing fines downward through the screen media while conveying oversize along the deck for discharge.
3. Efficient Discharge: Correctly sized product passes through the deck apertures, while oversize is discharged at the end of the deck for return to crushers or separate stockpiling.

Application Scope: Primary sizing (scalping) of runofoven coke, final product separation for blast furnace (2575mm) and foundry cokes, dedusting operations, and pet coke classification.

Limitations: Not designed for sticky materials without specialized screen media. Maximum feed size is limited by deck opening and structural design; typically handles lumps up to 300mm.

3. CORE FEATURES

Modular Deck System | Technical Basis: Independently tensioned polyurethane or steel wire panels | Operational Benefit: Panels can be replaced individually without full deck dismantling, reducing changeout time by up to 65%. | ROI Impact: Cuts maintenance labor costs and significantly reduces screen media downtime.

Dual CounterRotating Eccentric Shafts | Technical Basis: Synchronized masses generating a true linear motion | Operational Benefit: Provides consistent material travel speed and optimal stratification with minimal power consumption per ton processed. | ROI Impact: Delivers higher screening efficiency (typically 9295%) for reduced recrush loads and lower energy costs.

DustEncapsulated Vibrator Assemblies | Technical Basis: Labyrinth seals & pressurized grease purge systems | Operational Benefit: Isolates critical bearings from abrasive coke dust ingress, the primary cause of bearing failure. | ROI Impact: Extends bearing service life by over 40%, preventing costly unplanned stoppages.

HuckBolted Construction | Technical Basis: Highshear strength aircraftstyle fasteners | Operational Benefit: Creates a rigid frame that resists metal fatigue from constant vibration, eliminating weld failures. | ROI Impact: Ensures structural integrity over a 10+ year lifespan, protecting your capital investment.

Variable Slope Adjustment | Technical Basis: Hydraulic or mechanical deck angle modification (1525 degrees) | Operational Benefit: Operators can finetune material retention time based on moisture content or throughput requirements. | ROI Impact: Optimizes efficiency for varying feed conditions without sacrificing product consistency.

AntiBlinding Systems | Technical Basis: Optional ball tray decks or flexible urethane cleaning rings | Operational Benefit: Continuous microimpact dislodges particles trapped in screen apertures. | ROI Impact: Maintains design capacity and product quality over extended runs, maximizing uptime.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (Accuracy) | 8588% typical for circular motion screens| Consistent 9295% achievable with linear motion & optimized decks| +8% reduction in misplaced material |
| Bearing Service Life (L10) in Coke Duty| ~8,000 10,000 hours| >14,000 hours with sealed vibrator design| +40% longer operational life |
| Deck Panel ChangeOut Time| Full deck bolt removal (68 hours)| Individual panel replacement (23 hours)| ~65% faster maintenance |
| Energy Consumption per Ton Processed| Baseline (100%)| Optimized mass & drive system reduces draw| Up to 15% lower energy use |
| Structural Frame Integrity| Conventional welded design prone to crack initiation at stress points| Huckbolted monolithic frame resists fatigue failure| Field data shows >90% reduction in framerelated weld repairs |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in widths from 1.2m to 3.6m; lengths from 4.8m to 10m. Capacities from 200 TPH to over 2500 TPH depending on aperture size and material characteristics.
Power Requirements: Drive motors range from 2 x 7.5 kW to 2 x 55 kW (400/690V, 50/60Hz). Total installed power depends on machine size and load.
Material Specifications: Deck frames: Hardox or equivalent abrasionresistant steel. Side plates: Mild steel with replaceable abrasion liners. Screen Media Options: Tensioned polyurethane panels (most common), rubberclad perforated plate, or woven wire cloth.
Physical Dimensions: Varies significantly by model. Example Model CVC2448: Overall length ~9m; width ~3m; height ~2.5m; weight approx. 12,500 kg.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Enclosed vibrator design allows reliable operation in highdust environments typical of coke plants.

6 APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feed Preparation

Challenge A major steel producer faced consistent blinding on their circular screens due to seasonal moisture variation in met coke.This caused excessive oversize carryover into the BF feed line,failing granulometry specs every winter season.Solution Installation of two widebody linear Coke Vibration Screens equipped with antiblinding ball trays.Solution Implementation Two widebody linear Coke Vibration Screens equipped with antiblinding ball trays were installed as final product screens.results Results Within one month,screening efficiency stabilized at94%.Oversize carryover was eliminated,and winterseason downtime for manual screen cleaning was reduced by80%.

Petroleum Coke Calcining Plant – Product Classification

Challenge A calciner needed precise separation of petcoke into three fractions(5mm,+515mm,+15mm)for different market grades.Their existing screens generated excessive fines(5mm)dust due aggressive vibration degrading fragile coke.results Results The plant switched to a tripledeck Coke Vibration Screen with precisely tuned stroke length frequency.solution Implementation A tripledeck Coke Vibration Screen with precisely tuned stroke length frequency was implemented.results Results Product yield improved notably.The+15mm lump fraction increased by7%,maximizing premium sales.Dust generation at the screen fell by an estimated30%,improving plant environment

Foundry Coke Producer – Scalping Oversize

Challenge An aging scalping screen before primary crushing suffered chronic structural weld failures every6months,causing72hour unplanned outages.solution Implementation A heavyduty Huckbolted frame Coke Vibration Screen replaced it handling300mm+feed material.results Results After24months continuous operation zero structural repairs have been required.Maintenance shifted entirely predictable component inspections

Commercial Considerations

Pricing tiers are structured based on machine size construction level required duty

Standard Duty Series For general petcoke lower capacity metcoke applications.Pricing typically ranges$85000$220000 USD FOB

HeavyDuty Series For highcapacity abrasive metcoke primary scalping.Includes enhanced liners vibrators.Pricing typically ranges$180000$450000 USD FOB

Optional Features Customizable feed boxes discharge hoods multiple discharge points dust encapsulation covers various anti blinding systems rubber buffer isolators Condition monitoring sensors vibration temperature probes

Service Packages Include installation supervision commissioning support operator training Extended warranty plans Critical spare parts kits Annual inspection maintenance contracts

Financing Options We work with third party financial institutions offer equipment leasing structures operating leases capital leases facilitate cash flow management New system acquisition

FAQ Frequently Asked Questions

Q How do I determine correct size model my plant
A Selection requires analysis key parameters target throughput tons hour feed particle distribution percentage desired cut point mm moisture content Our application engineers provide detailed questionnaire guide specification process

Q Can this screen replace our existing circular motion unit footprint
A Linear motion screens often require longer footprint similar width Most retrofit projects involve minor modifications feed chute discharge hoppers Engineering drawings are provided feasibility review prior quotation

Q What typical lead time delivery
A For standard configurations lead time ranges12to20weeks order acknowledgment depending current production schedule Expedited options may be available additional cost

Q Are spare parts readily available
A Yes We maintain global inventory critical wear parts vibrator assemblies deck panels tensioning components Standard parts are shipped within48hours emergency orders Longer lead items are clearly identified manuals

Q Do you offer performance guarantees
A Yes Our proposals include guaranteed minimum capacity tons hour specified material conditions guaranteed screening efficiency percentage based controlled test conditions These are formalized sales contract