H1: HighCapacity Custom Coke Vibration Screens for Precision Sizing and Scalping

1. PAINPOINT DRIVEN OPENING

Managing coke feedstock quality presents persistent challenges that directly impact downstream process efficiency and plant profitability. Are you contending with:
Sizing Inconsistencies: Variable feed leading to offspec product, causing rejections or penalties from blast furnace operators.
Excessive Fines Generation: Conventional screening methods contributing to excessive breakage of highvalue lump coke, eroding yield and revenue.
Unplanned Downtime: Frequent screen cloth changes and structural fatigue from abrasive coke abrasion, resulting in costly production halts.
Scalping Inefficiencies: Inadequate removal of oven debris (silicon carbide, "oven stone") and oversized material, risking damage to crushers and conveyors.
High Maintenance Burden: Bearings, springs, and decks failing prematurely under heavy loads, driving up spare parts costs and labor hours.

If these operational costs are affecting your bottom line, the specification of your screening equipment is a critical leverage point. A purposeengineered Custom Coke Vibration Screen is not merely a commodity filter; it is a core component for achieving grade control, protecting capital equipment, and maximizing throughput.

2. PRODUCT OVERVIEW

A Custom Coke Vibration Screen is a heavyduty vibratory screening machine specifically engineered for the dry separation and classification of metallurgical coke. Its design prioritizes durability, accurate particle separation, and highvolume handling in harsh environments.

Operational Workflow:
1. Feed Introduction: Raw coke from the quench car or storage is conveyed onto the screen's robust feed box.
2. Stratification & Separation: A highenergy, linear or elliptical vibratory motion stratifies the material bed. Smaller particles pass through precisely sized screen deck apertures.
3. Fraction Discharge: Correctly sized lump coke discharges from the deck end as product. Undersize (coke breeze) passes through to a separate collection chute. Oversize material or scalped debris exits via a dedicated reject spout.

Application Scope & Limitations:
Scope: Primary sizing of hot or quenched metallurgical coke, scalp removal of oven debris (SiC), dedusting (breeze removal), and routing of multiple product fractions. Suitable for sinter plant feed preparation.
Limitations: Not designed for wet screening applications or for materials with high moisture content that causes blinding. Maximum capacity is defined by physical aperture size and material bulk density.

3. CORE FEATURES

Modular Deck System | Technical Basis: Independently tensioned panel frames | Operational Benefit: Allows for rapid replacement of individual screen sections without full deck shutdown | ROI Impact: Reduces maintenance downtime by up to 60% per changeout

AbrasionResistant Lining Package | Technical Basis: Bolton AR steel plates in highwear zones (feed box, discharge lips) | Operational Benefit: Protects structural steel from wear, extending mainframe service life by multiples | ROI Impact: Eliminates costly structural repair campaigns; defers capital replacement

HeavyDuty Coil Spring Isolation | Technical Basis: Progressiverate steel coil springs | Operational Benefit: Absorbs dynamic loads while transmitting minimal vibration to the support structure | ROI Impact: Reduces foundational stress cracks and associated civil maintenance costs

Centralized Greasing Lube System | Technical Basis: Manifold with lines to all bearing points | Operational Benefit: Ensures consistent lubrication of vibrator shaft bearings under high thermal stress | ROI Impact: Extends bearing service life; prevents catastrophic failure causing extended unplanned downtime

Variable Amplitude & Frequency Drive | Technical Basis: Adjustable eccentric weights & VFD motor control | Operational Benefit: Operators can tune screen motion for optimal stratification with varying feed rates or coke characteristics | ROI Impact: Maintains screening efficiency across shifts, maximizing consistent product yield

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Custom Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screen Cloth Life (Lump Deck) | Standard woven wire mesh | Reinforced polyurethane panels with steel backing grid | +150200% lifespan |
| Bearing MTBF (Mean Time Between Failure) | ~8,000 hours in harsh service | >12,000 hours with specialized sealing & lube systems| +50% operational reliability |
| Screening Efficiency at 80mm cut point| ~8590% efficiency| Consistently >94% efficiency via optimized throw & angle| +59% more product on spec |
| StructureBorne Vibrations Transmitted to Support| Significant harmonic vibration observed| Isolated via tuned spring system & subframe design| Reduction of >70% measured vibration |
| Total Cost of Ownership (5year period)| High consumable & repair costs| Predictable maintenance schedule with protected structure| Documented 2535% lower TCO |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Models from 500 TPH to 2,500+ TPH capacity for metallurgical coke (bulk density ~0.5–0.7 t/m³).
Power Requirements: Driven by 15 kW to 45 kW vibrator motors (depending on size), standard 400/690V AC supply.
Material Specifications: Mainframe constructed from heavyduty S355JR steel; critical wear areas lined with Hardox 400/500 or equivalent AR plate; corrosionresistant paint system.
Physical Dimensions: Single or doubledeck configurations; typical deck widths from 1.8m to 3.6m; lengths from 4.8m to 7.2m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; capable of handling hot coke up to ~200°C with heatresistant components.

6. APPLICATION SCENARIOS

Integrated Steel Plant Blast Furnace Feedstock Preparation

Challenge: A major mill faced inconsistent blast furnace performance linked to variable coke size distribution and periodic contamination from oven debris.
Solution: Installation of a primary scalping Custom Coke Vibration Screen with a coarse top deck for debris removal and a lower sizing deck.
Results: Achieved consistent lump coke sizing (>80mm) with <2% oversize/undersize variability; eliminated downstream crusher damage events; recorded a 1.5% reduction in blast furnace coke rate within one quarter.

Merchant Coke Producer Yield Optimization

Challenge: The client's existing screens generated excessive fines (10mm breeze), converting highvalue lump product into lowerrevenue streams.
Solution: Implementation of a twindrive Custom Coke Vibration Screen featuring polyurethane decks designed for reduced abrasioninduced breakage.
Results: Fines generation reduced by an average of 18%; lump coke yield increased correspondingly, directly boosting annual revenue by an estimated $1.2M at prevailing market prices.

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are determined by size/capacity (deck surface area), material specifications (standard vs premium AR linings), drive configuration (single vs dual), and control sophistication (basic vs PLCintegrated).

Optional Features:
Dust encapsulation hoods
Aircooled vibrator units
Advanced condition monitoring sensors (vibration/temperature)
Stainless steel components for highly corrosive environments

Service packages typically include:
Extended warranty plans covering bearings and structural integrity
Annual inspection & vibration analysis programs
Onsite training for operation & preventative maintenance

Financing options available include capital purchase through project finance partners or longterm operating lease agreements designed to preserve capital budgets.

8 FAQ

Q1 Are your screens compatible with existing conveyor layouts?
A1 Our engineering team designs custom feed boxes discharge heights based on your specific layout drawings ensuring seamless integration into your current transfer points

Q2 What is the expected impact on my overall plant noise levels?
A2 Field data shows our fully isolated designs typically operate below dB(A) levels specified by most industrial health standards reducing noise pollution concerns

Q3 How does this solution address screen blinding issues common with sticky materials?
A3 While primarily dry screens we offer optional deck heating systems ball tray decks antiblinding devices tailored if minor moisture is present

Q4 What are typical lead times?
A4 Lead times vary based on complexity Standard configurations require weeks while fully customized units require weeks following finalized engineering approval

Q5 Can you provide performance guarantees?
A5 Yes we provide contractual guarantees on throughput capacity screening efficiency based on agreedupon feed material analysis

Q6 What spare parts inventory do you recommend?
A6 We provide a critical spares kit recommendation list including tensioning hardware specialized gaskets drive belts ensuring minimal waiting time for common wear items