H1: Optimize Screening Efficiency & Reduce Environmental Impact with Advanced Coke Vibration Screens

Subhead: Engineered for highvolume, highabrasion service in coke handling and classification, delivering uptime, precision, and compliance.

1. PAINPOINT DRIVEN OPENING

Is your coke screening operation a source of constant cost, downtime, and environmental concern? For plant managers overseeing coke production for blast furnaces or foundries, inefficient screening directly impacts downstream process stability and profitability. Common challenges include:

Excessive Dust Emission & Spillage: Poorly sealed or highimpact screening generates fugitive dust, creating environmental compliance risks, housekeeping burdens, and product loss.
Premature Wear & Unplanned Downtime: The highly abrasive nature of metallurgical coke rapidly degrades standard screen decks and components, leading to frequent replacements and costly production interruptions.
Inefficient Fines Separation: Inconsistent vibration patterns or screen blinding result in undersize material contaminating product coke, or valuable fines being lost, directly affecting product quality and revenue.
High Maintenance Labor & Parts Costs: Conventional screens often require complex, timeconsuming maintenance routines for bearing checks, drive alignment, and deck changes, straining your maintenance budget.
Energy Inefficiency: Outdated vibrator technology or unbalanced mass systems draw excessive power without delivering proportional screening performance.

Are you seeking a solution that extends component life, contains material effectively, reduces operational costs, and maintains precise grading under heavy load?

2. PRODUCT OVERVIEW

The EcoFriendly Coke Vibration Screen is a heavyduty linear motion screening machine designed for the sizing and scalping of metallurgical coke. It is built to handle large feed rates while minimizing environmental footprint through superior containment design.

Operational Workflow:
1. Controlled Feed: Coke from the crusher or oven is directed onto the feed box of the vibration screen.
2. Precise Stratification & Separation: A dualshaft vibrator assembly generates a linear throwing motion, stratifying material efficiently across multiple deck levels (typically 13). Sized apertures separate oversize (return), product coke (middlings), and fines.
3. Contained Discharge: Sealed discharge spouts direct each product stream—oversize returnable for crushing; onspec coke to blast furnace bins; fines to briquetting or sintering—while minimizing dust generation at transfer points.

Application Scope:
Primary sizing of runofoven coke.
Scalarping of oven coke ahead of crushers.
Dedusting and fines removal from blast furnace coke.
Sinter feed preparation.

Limitations:
Not designed for sticky or highmoisture materials without specialized deck treatments.
Maximum capacity is governed by particle size distribution and separation sharpness requirements.

3. CORE FEATURES

Modular Deck System | Technical Basis: Independent pretensioned polyurethane or rubber panel sections | Operational Benefit: Panels can be replaced individually in under 15 minutes without removing entire deck structure. Reduces downtime for screen media changes by up to 70%. | ROI Impact: Lowers labor costs per changeout and increases plant availability for production.

MultiPoint Sealing & Dust Encapsulation | Technical Basis: Labyrinth seals combined with durable rubber dust curtains at all strategic transfer points. | Operational Benefit: Effectively contains dust at feed inlet, between decks, and at discharge spouts. Your plant meets stricter emission standards with reduced airborne particulate. | ROI Impact: Mitigates risk of noncompliance fines and reduces cleanup costs. Preserves product yield.

HeavyDuty Vibrator Assembly with Lubrication System | Technical Basis: Double eccentric shaft vibrators housed in a rigid frame with forcedfeed lubrication circulation. | Operational Benefit: Provides consistent linear stroke under variable load conditions. Continuous oil filtration extends bearing life significantly in highshock applications. | ROI Impact: Field data shows a 4060% increase in mean time between failures (MTBF) for vibrator assemblies compared to greaselubricated units.

EnergyEfficient Drive Configuration | Technical Basis: Directcoupled motor drive with frequency inverter option for soft start/stop and stroke adjustment.| Operational Benefit: Reduces peak electrical demand during startup by up to 60%. Allows operators to finetune stroke for optimal efficiency based on feed conditions.| ROI Impact: Lowers operational power costs annually; reduces mechanical stress on driveshafts and belts.

AbrasionResistant Lining Package | Technical Basis: Bolton wear liners made from AR400 steel or cast basalt at highimpact zones (feed box, side plates).| Operational Benefit: Protects the main screen body from wearthrough damage caused by direct coke impact.| ROI Impact: Eliminates need for major structural repairs over the machine's lifespan; protects capital asset value.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | EcoFriendly Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Screen Deck Change Time | 812 hours (full crew) | 50% faster |
| Bearing Service Life (Vibrator) | ~8,000 10,000 hours| Up to 16 ,000 hours documented| Up to +60% |
| Dust Emission at Discharge Points| Visible plume requiring extraction| Contained discharge; minimal visible emission| >80% reduction observed |
| Power Consumption per Ton Screened| Baseline (100%)| With optimized drive & stroke control| Up to 1520% |
| Media Life (Deck Panels)| Standard wire mesh / mild steel panels| Specialized polyurethane / rubber panels| +200300% typical |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: From 500 TPH up to 2 ,500 TPH depending on aperture size and deck configuration.
Screen Decks: Single , double , or triple deck configurations available.
Deck Size Range: Widths from 1 .5m up to 3 .0m; Lengths from 4 .5m up to 9 .0m .
Drive Power: Motors from 15 kW up to 55 kW , depending on size/load . Voltage as per client specification (e.g.,400V/50Hz ,460V/60Hz).
Vibration Frequency & Stroke: Adjustable via eccentric weights ; typical operating range of9001000 RPM with stroke of812mm .
Construction Materials: Main frame : heavyduty structural steel . Wear surfaces : AR400 liners standard ; optional ceramic/composite liners . Decks : Hightensile frame with polyurethane/rubber/modular panels .
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C . Enclosed motors suitable for outdoor installation .

6\. APPLICATION SCENARIOS

Integrated Steel Plant Blast Furnace Feed Preparation

Challenge: A major steel producer faced severe dust emissions during final screening of blast furnace coke , incurring regulatory notices . Their existing screens also suffered frequent bearing failures every9 months due to contamination .
Solution: Installation of two tripledeck EcoFriendly Coke Vibration Screens featuring full encapsulation seals , forcedlube vibrators ,and modular polyurethane decks .
Results: Visible dust emissions were eliminated at the source , achieving compliance . Bearing service intervals extended beyond24 months . Annual maintenance costs related to the screening station decreased by an estimated35%.

Foundry Coke Producer

Challenge: Inconsistent sizing from old screens led to excessive fines in product shipped to foundries , causing customer complaintsand price penalties . Downtimefor deck changes halted the entire processing line .
Solution: A customsized doubledeck unit was installed as a replacement scalper aheadof existing equipment,fittedwith precisionaperture decksand aninverterfor stroke optimization .
Results: Product consistency improved dramatically ; offspec material duefines contamination droppedby over90%. The modular deck system reduced planned changeout downtimefrom10 hoursto3 hours,increasing annual throughput .

7\. COMMERCIAL CONSIDERATIONS

Our EcoFriendly Coke Vibration Screens are offeredin tiered configurations tomatch specific operational budgetsand performance requirements:

Standard Tier: Core robust constructionwith basic sealingand conventional vibrators.Idealfor less stringent environments where initial capital costis paramount .
Optional Features: Basic wear liners ,standard motors .
Service Package:12month parts warranty .

Performance Tier(Most Common): Includes all core features listed above(forced lube vibrators ,modular decks ,enhanced sealing). Recommendedfor continuous operation plants seeking optimal total costof ownership .
Optional Features: Variable frequency drive(VFD)for soft start&optimization,custom discharge spouts,dust extraction flange connections .
Service Package: Extended36month drivetrain warrantyavailable.Preventive maintenance inspection contracts .

Premium Tier: Fully customized solutionwith premium materials(ceramic composite liners),advanced condition monitoring sensors(vibration,temperature),and automated lubrication systems.For criticalpath operations demanding maximum intelligenceand uptime .
Optional Features: Full automation integration package,predictive maintenance software dashboard .
Service Package: Comprehensive lifecycle support contractincluding remote monitoring .

Financing options including equipment leasingand rentaltoown programs are availableto help manage capital expenditure.Full installation supervisionand operator training servicesare providedwith every unit .

8\. FAQ

Q1:What isthe lead timefor deliveryof acustomconfiguredcoke vibration screen?
A1:Largely dependenton sizeand specification.For Performance Tier modelswith standard features,the lead time typically rangesfrom14to18 weeksfrom order confirmationto exworks delivery.Customizations may extend this timeline slightly .

Q2:Canyour screens replaceourexisting unitswithout major foundation modifications?
A2:The design teamcan provide retrofit solutions.In many cases,the base dimensionsand dynamic load characteristicscan be engineeredtomatch existing foundationsandsurrounding chuteworkto minimize civil workrequirements.Detailed site surveysare conductedto confirm compatibility .

Q3:Whatisthe expected operational lifeforthe main structural frame?
A3:The main structural frameis designed fora minimum service lifeof20+yearsunder normal operating conditionswhen protectedbythe specified wear liner package.This representsa longterm capital asset investment .

Q4:Doyou offerdeck panelscompatiblewith othermanufacturer'sscreen frames?
A4:The modular tension systemis proprietarytothis design.For optimal performanceandsafety,wesupplycomplete replacementdeck assembliesdesigned specificallyfor ourframes.We donot recommendfittingour panelsinto othermanufacturer's equipmentdue tounpredictable dynamic behavior .

Q5:Whatisthe recommended preventative maintenance scheduleforthe forcedlube vibrator system?
A5:The systemrequires quarterly checksof oil levelandsight glass condition.Oil analysisis recommendedannually,andafull oil changeevery24 monthsof continuous operation.This schedulehas proven effectivein extending component lifeas notedinthe field data .

Q6:Arethere financing optionsavailablefor international buyers?
A6:Yes,in partnershipwithmajor international export credit agenciesandleasing companies,weprovide structured financing solutionsformost global markets.This can include progress payment structuresalignedwithmilestonesduring manufacturing .

Q7:Canthescreen be integratedinto ourplant's existing PLC/DCS control system?
A7:The optional VFDsand condition monitoring sensorscomewithmodbus RTUorProfibus communication protocolsas standard,making integration straightforward.Control signalsfor start/stop,speed adjustment,and fault feedback canbe easily wiredinto your central control room