Targeting Plant Managers, Procurement Specialists & Engineering Contractors: Optimize Your Coke Sizing & Classification with Advanced Vibration Screen Technology

1. Addressing Critical Operational Challenges in Coke Handling

Is your coke screening process a source of inefficiency and unexpected cost? For operations dependent on consistent coke quality for blast furnace feed, foundry operations, or anode production, subpar screening directly impacts downstream performance and profitability. Common pain points include:
Excessive Fines Generation & Product Degradation: Conventional screens with highimpact loading can fracture coke, increasing the percentage of undersize material (10mm/6mm) and reducing the yield of valuable lump product. This represents direct revenue loss.
Frequent Downtime for Screen Cloth Changes: Blinding and pegging of screen meshes by moist or sticky coke halts production. Industry data indicates average downtime for screen maintenance can exceed 15 hours per month per line.
High Energy Consumption & Structural Fatigue: Inefficient vibratory motion requires more power to move material, while excessive vibration transmission to support structures leads to premature wear and potential foundation issues.
Inconsistent Sizing & Contamination: Inaccurate separation results in oversized fines entering the lump stream or valuable lump coke being lost to the fines conveyor, compromising product specifications and customer contracts.
Harsh Environmental Working Conditions: Dust emission at transfer points and high noise levels create noncompliance risks and operator health concerns.

Are you evaluating solutions to reduce total cost of ownership, extend mean time between failures (MTBF), and protect your premium coke product integrity?

2. Product Overview: HeavyDuty EcoFriendly Coke Vibration Screens

Our engineered line of EcoFriendly Coke Vibration Screens is designed for highcapacity sizing (scalping, grading) of metallurgical (met) coke, petroleum coke (petcoke), and foundry coke. These screens prioritize material preservation while maximizing throughput and operational cleanliness.

Operational Workflow:
1. Controlled Feed: Coke is fed onto the screen via a controlledrate feeder, minimizing impact load on the screen cloth.
2. Efficient Stratification & Separation: A combination of precise vibratory motion and optimized deck layout stratifies material, allowing accurately sized particles to pass through the screen media.
3. Clean Discharge: Sized fractions (e.g., lump, nut, breeze) are discharged into separate chutes with minimal intermixing for downstream processing or loading.

Application Scope: Primary and secondary screening of dry or slightly moist coke in battery discharge stations, crushing plant circuits, and loadout facilities. Ideal apertures from 4mm to 80mm.

Limitations: Not designed as a dewatering screen for slurry applications or for handling highly adhesive materials without specialized screen media.

3. Core Features: Engineered for Performance & ROI

Our design philosophy focuses on measurable improvements in reliability and efficiency.

Modular Polyurethane Screen Decks | Technical Basis: Abrasionresistant elastomer with openarea optimization | Operational Benefit: Reduces blinding by up to 60% compared to steel wire cloth; dampens noise by approximately 810 dBA; allows for faster panel changeout | ROI Impact: Cuts maintenance downtime by an estimated 40% and extends media life by 35x.

DustEncapsulated Deck Design | Technical Basis: Integrated skirt boards and sealed discharge hoods with dust extraction ports | Operational Benefit: Contains dust at critical transfer points, reducing airborne particulate matter | ROI Impact: Lowers housekeeping costs and facilitates compliance with site environmental regulations.

VariableFrequency Drive (VFD) Control System | Technical Basis: Precision control of vibratory motor speed/amplitude | Operational Benefit: Operators can finetune screening action for varying feed rates or moisture content to optimize efficiency; softstart capability reduces mechanical stress | ROI Impact: Achieves up to 20% energy savings versus fixedspeed drives; extends bearing life.

LowNoise Vibrator Assemblies | Technical Basis: Enclosed geartype vibrators with highgrade lubricants and precision bearings | Operational Benefit: Provides consistent linear or elliptical motion with sound levels consistently below 85 dB(A) at 1 meter | ROI Impact: Creates a safer operator environment, reducing hearing protection requirements.

Base Frame Vibration Isolation | Technical Basis: Highperformance rubber or spring isolators between the screen body and support structure | Operational Benefit: Absorbs up to 95% of dynamic loads, preventing transmission to the building structure | ROI Impact: Eliminates costly structural reinforcement needs and prevents vibrationinduced fatigue failures in surrounding equipment.

4. Competitive Advantages: Quantifiable Performance Metrics

| Performance Metric | Industry Standard Challenge | Our EcoFriendly Coke Vibration Screen Solution | Documented Advantage |
| : | : | : | : |
| Screen Media Lifespan (Abrasive Coke) | Steel Wire Cloth: 23 Months | Modular Polyurethane Panels | +300% to +500% Improvement |
| Energy Consumption per Ton Screened| FixedSpeed Drives at Constant Load| VFDOptimized Operation| Up to 20% Reduction |
| Annual Maintenance Downtime| ~180 hours (estimates for cloth changes/bearing service)| ~108 hours (projected)| Up to 40% Reduction |
| NearScreen Noise Emission| Often >90 dB(A)| Engineered 5 dB(A) Reduction |

5. Technical Specifications

Model Range & Capacity: Sizes from 1.2m x 3.0m single deck to 2.4m x 6.0m triple deck configurations; capacities from 50 TPH to over 800 TPH depending on aperture size and material characteristics.
Power Requirements: Driven by twin outofbalance vibrator motors ranging from 7.5 kW to 30 kW per motor, supplied for global voltages (380V480V /5060Hz).
Material Specifications: Deck frames constructed from abrasionresistant steel (AR400 liners standard); side plates from mild steel; polyurethane media in multiple compound grades for specific abrasion/impact profiles.
Physical Dimensions: Varied by model; emphasis on low headroom design for easier installation in existing buildings.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; IP65 protection standard on vibrator motors; suitable for outdoor installation with optional weather covers.

6.Application Scenarios

[Integrated Steel Mill Blast Furnace Feed] Challenge: A major mill experienced excessive fines generation (10mm) at their battery screening station, losing premium lump coke (>25mm) yield due to aggressive screening action. Frequent wire mesh failures caused biweekly stoppages.Solution: Installation of two large singledeck EcoFriendly Coke Vibration Screens with polyurethane panels sized at a nominal25mm aperture.Results: Fines generation reduced by18%; screen panel replacement interval extended from2 weeksto9 months; annualized yield increase valued against lump premium pricing.

[Petroleum Coke Calcining Plant Product Grading] Challenge: A calciner needed precise separation of calcined petcoke into3 fractions (+25mm,25/+12mm,12mm) but struggled with dust emission at open transfer pointsand rapid cloth wearfrom abrasive material.Solution: Implementationof a tripledeck enclosedscreenwith our dustencapsulated designand specialized polyurethane screenshapes.Results: Dust emissionsatthescreenhouse measured below required permit levels;media lifespan increasedby400%;product segregation accuracy improvedto98%.

7.Commercial Considerations

Pricing Tiers:
Standard Series: Robust base modelsfor standardduty cyclesand environments.
HighCapacity Series: Reinforced designsfor throughputs exceeding600TPHwithpremium components.
Modular Upgrade Kits: Retrofittable packages(ex.VFDkits,dust hoods)for existing equipment upgrades.

Optional Features:
Heated deckscreensformoisture mitigationin humid climates.
Different typesofscreenmedia(perforated plate,rubber,polyurethane)
Advanced condition monitoring sensors(vibration,temperature)onvibrator bearings.
Walkways,ladders,and safety guarding packages.

Service Packages:
Extended warrantyoptions(upto36months).
Annual inspectionand vibration analysis contracts.
Onsite trainingfor operationand preventive maintenance.

Financing Options: Flexible commercial leasingstructuresandrentaltoownprogramsare availableto spread capital expenditure.

8.Frequently Asked Questions(FAQ)

Q1:What isthe lead timefora typicalcoke vibrationscreen unit?
A1:Builttimes varybycomplexity,butstandardmodelsare typicallyavailablewithin1216weeksfromorderconfirmation.Longleaditemslikecustommotorsare identifiedearlyintheprocess.

Q2:Canyourscreensbe integratedintoourexistingPLCcontrol system?
A2:TheVariableFrequencyDrive(VFD)control systemcomesstandardwithindustrystandardcommunicationprotocols(ProfibusDP,Ethernet/IP).Our engineerswill provideall necessary documentationfor integrationbyyour controls team.

Q3:Whatisthe expectedoperational lifespanofthisequipment?
A3:Thecore structureisdesigned fora minimumservice lifeof15+yearsundernormaloperatingconditions.Criticalwearcomponentslikescreenmediaandvibrator bearingshave definedlifespansbasedonoperatinghours,material abrasiveness,andmaintenance scheduleswhichwe outlineinour manuals.

Q4:Doyouofferperformance guarantees?
A4:A throughputandefficiency guaranteeisprovidedbasedonagreeduponfeedmaterialanalysisandspecifications.Guaranteescover separation accuracyandratedcapacityunder defined conditions.

Q5:Whatlevelofsparesinventoryshouldwemaintainonsite?
A5:A recommendedspareslistforthe firsttwoyearsofoperationisprovided.Thisfocusesoncriticalwearitemsandspecificcomponentsthatmayhave longerprocurement times.We adviseholdingbasic gaskets,sets offasteners,andone setofscreenpanelsperunitonsite.

Q6:Isthe polyurethanemedia compatiblewithhotcoke?
A6:Specifichightemperaturepolyurethanecompoundsare availableforservice where feedtemperaturesconsistentlyexceed80°C.We will specifythe correctmaterial gradebasedonyour operatingdata duringthe quotation process.

Q7:Whatkindoffoundation preparationisrequired?
A7:Due tothereduced dynamicforcesfromour isolation system,foudnation requirementsare lessrigorousthanforconventional screens.Detailedstaticanddynamicload drawingsare suppliedforall modelsforsubmissiontoyour civil engineeringteam