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Is Inconsistent Coke Sizing Costing You $50,000+ Per Shift in Rejects and Downtime?

In the metallurgical and petroleum coke processing industry, a single screen deck failure or a 2% deviation in particle size distribution can halt a calciner or disrupt a downstream anode plant. You face the daily challenges of:

• Blinding and Peening: Pegajoso, highmoisture coke fines clogging standard screens, reducing effective open area by up to 40%.
• Fatiga estructural: Constant highGforce vibration cracking welds on nonreinforced frames, leading to unplanned 12hour maintenance shutdowns.
• Inconsistent Cut Points: Inefficient stratification causing oversize material to contaminate fines, forcing recrushing cycles that waste energy and wear out crushers.
• Riesgos de cumplimiento de seguridad: Operating without proper CE certification exposes your plant to regulatory fines and liability for worker safety.

Can your current screening equipment handle the abrasive, highimpact nature of green and calcined coke while maintaining a precise 6mm to 50mm separation? If not, your profit margin is being screened out.

Descripción general del producto: The CE Marked Coke Vibration Screen Distributor

Este es un trabajo pesado, linearmotion vibratory screener specifically engineered for the classification and distribution of petroleum coke, coque metalúrgico, y coque de fundición. It is designed to handle hightonnage feed streams (arriba a 500 TPH) while providing a precise, multideck separation.

Flujo de trabajo operativo:
1. Entrada de feed: Raw coke enters the distributor via a chute, landing on a wearresistant feed box to disperse the material evenly across the full screen width.
2. Estratificación: Highamplitude, lowfrequency vibration (700900 RPM) causes heavier, larger particles to rise to the top layer, while fines migrate to the bottom deck.
3. Clasificación: Material passes through a series of polyurethane or heavyduty woven wire mesh decks (típicamente 24 cubiertas) para un dimensionamiento preciso (p.ej., +50milímetros, 2550milímetros, 1025milímetros, 10milímetros).
4. Distribución: Sized fractions are discharged through dedicated spouts, directly feeding downstream conveyors, storage bins, or calcining kilns.
5. Oversize Reject: Material de gran tamaño (+50milímetros) is directed to a crusher circuit or reject chute.

Ámbito de aplicación: Ideal for green coke handling at refineries, calcined coke processing at anode plants, and blast furnace coke sizing at steel mills.
Limitaciones: Not recommended for wet, sticky materials with >15% surface moisture without the addition of a heated deck or ball tray cleaning system.

Características principales

Conjunto de excitador de servicio pesado | Base técnica: Dualshaft, counterrotating gearbox | Beneficio operativo: Generates a linear stroke of 1014mm, ensuring deep bed stratification without vertical lift | Impacto del retorno de la inversión: Reduces power consumption by 15% compared to circular motion screens, lowering annual energy costs by $8,000$12,000

CE Certified Structural Integrity | Base técnica: Análisis de elementos finitos (FEA) designed side plates with 10mm thick Strenx 700 acero | Beneficio operativo: Eliminates frame cracking under continuous 24/7 operación | Impacto del retorno de la inversión: Extends equipment lifespan to 15+ años, reducing capital replacement costs by 30%

Paneles modulares de pantalla de poliuretano | Base técnica: Slotopening, abrasionresistant polyurethane (Orilla A 90) | Beneficio operativo: Reduces blinding from coke fines; panels are interchangeable in 15 minutos | Impacto del retorno de la inversión: Increases screen deck life by 3x over woven wire, ahorro $4,500 annually in mesh replacement and labor

Integrated Feed Distributor Box | Base técnica: Angled, replaceable AR400 steel liners | Beneficio operativo: Prevents material segregation at the feed point, ensuring even load distribution | Impacto del retorno de la inversión: Mejora la eficiencia del cribado al 812%, reducing recirculating loads and energy waste

Sistema de lubricación automática | Base técnica: Centralized grease manifold with programmable timer | Beneficio operativo: Garantiza una lubricación constante de los rodamientos sin intervención del operador. | Impacto del retorno de la inversión: Extends bearing life by 2x, preventing catastrophic failures that cost $15,000+ in repairs and lost production

Vibration Isolation Base Frame | Base técnica: Steel coil springs with 95% eficiencia de aislamiento | Beneficio operativo: Transmits less than 5 kN of dynamic force to the support structure | Impacto del retorno de la inversión: Eliminates the need for expensive reinforced concrete foundations, ahorro $20,000 in civil works per installation

Ventajas competitivas



| Métrica de rendimiento | Estándar de la industria (Standard Screen) | CE Marked Coke Vibration Screen Distributor | Ventaja (% mejora) |
| : | : | : | : |
| Eficiencia de detección (6mm cut) | 7580% | 9295% | +1520% |
| Deck Life (Poliuretano) | 69 meses | 1824 meses | +100150% |
| Garantía del marco estructural | 1 año | 5 años (with FEA certification) | +400% |
| Nivel de ruido a 1m | 95 dB(A) | 82 dB(A) | 14% (safer for operators) |
| Tiempo de cambio (Cubierta) | 4 horas (2man crew) | 45 minutos (1man crew) | 81% |
| Consumo de energía (por tonelada) | 0.8 kWh/tonelada | 0.55 kWh/tonelada | 31% |

Especificaciones técnicas

| Parámetro | Especificación |
| : | : |
| Modelo | CVD2448 (2.4mx 4,8m) |
| Capacidad | 250 500 TPH (depending on cut point) |
| Number of Decks | 2, 3, o 4 (configurable) |
| Área de pantalla | 11.5 m² per deck |
| Vibration Type | Movimiento lineal |
| Ataque | 10 14 milímetros (ajustable) |
| Frecuencia de vibración | 750 900 RPM |
| Potencia del motor | 2 incógnita 15 kilovatios (TEFC, IP55) |
| Material of Construction | Strenx 700 placas laterales, AR400 feed box |
| Medios de pantalla | Poliuretano (slot or square opening) |
| Operating Temperature | 20°C to +80°C (ambiente) |
| Peso (aprox.) | 12,500 kilos |
| Dimensiones (Largo x ancho x alto) | 6.2m x 3.0m x 2.8m |
| CE Certification | Sí (EN 12100, EN 602041) |

Escenarios de aplicación

Green Coke Dewatering & Sizing at a Refinery

Desafío: A Gulf Coast refinery was experiencing 30% downtime on their coke drum dewatering screens due to blinding from 8% contenido de humedad. Oversize material was damaging downstream crushers.
Solución: Installed a 3deck CE Marked Coke Vibration Screen Distributor with slotted polyurethane panels and a 12mm stroke.
Resultados: Screening efficiency increased to 94%. Crusher wear life doubled. Unplanned downtime dropped from 120 hours/year to 12 horas/año, ahorro $180,000 en producción perdida.

Calcined Coke Classification for Anode Production

Desafío: An aluminum smelter needed a precise 0.5mm to 6mm fraction for anode paste. Their existing screens produced high variability (+/ 1.5milímetros), causing anode quality issues.
Solución: Deployed a 4deck unit with a dedicated feed distributor to ensure even material spread.
Resultados: Particle size distribution tightened to +/ 0.3milímetros. Anode rejection rate fell from 4% a 0.5%. The ROI was achieved in 11 months due to reduced scrap and rework costs.

Blast Furnace Coke Screening at a Steel Mill

Desafío: A steel mill required a consistent +25mm fraction for their blast furnace. Their existing screens were structurally failing after 3 years due to high Gforces.
Solución: Replaced with a CEcertified unit featuring a heavyduty FEAdesigned frame and 5year structural warranty.
Resultados: Structural integrity issues eliminated. The +25mm fraction consistency improved to 98%. La planta logró un 15% reducción de la tasa de coque (kg coke per ton of iron) due to better burden permeability.

Consideraciones comerciales

Niveles de precios de equipos (ENGAÑAR, En fábrica):

• Modelo básico (2deck, manual lube): $85,000 $110,000
• Modelo estándar (3deck, lubricante automático, poly panels): $135,000 $175,000
• Modelo premium (4deck, lubricante automático, cubiertas climatizadas, monitoreo remoto): $195,000 $250,000

Características opcionales:

• Heated Screen Decks: +$18,000 (for highmoisture applications)
• Ball Tray Cleaning System: +$9,500 (for fine mesh, <3milímetros)
• Remote Vibration Monitoring System: +$12,000 (mantenimiento predictivo)
• Custom Chute Work & Support Steel: +$15,000 $30,000

Paquetes de servicios:

• Garantía estándar: 2 years on mechanical components, 5 years on structural frame.
• Plan de servicio extendido (ESP): $8,500/año (incluye 2 annual inspections, priority parts delivery, 24hour phone support).
• Full Turnkey Installation: $25,000 $45,000 (including commissioning and operator training).

Opciones de financiación:

• Net 30/60 términos para compradores calificados.
• Leasetoown options starting at $2,800/month for the Standard Model.
• Performancebased payment: 10% upfront, 90% upon achieving 90%+ screening efficiency guarantee.

Preguntas frecuentes

1. What is the maximum moisture content this screen can handle for green coke?
The standard unit handles up to 12% surface moisture. For moisture levels between 12% y 18%, we recommend the optional heated deck system to prevent blinding. Above 18%, a thermal drying step is advised before screening.

2. How does the CE certification impact my plant’s safety compliance?
The CE mark certifies compliance with the EU Machinery Directive (2006/42/CE). This includes a full risk assessment, safety circuit design, y documentación. For plants in regulated jurisdictions, this reduces liability and simplifies safety audits.

3. Can this screen be retrofitted into my existing support structure?
Sí. The vibration isolation base frame transmits less than 5 kN of dynamic force. Most existing steel structures rated for 10 kN can support this unit without reinforcement. We provide a free structural load analysis with a purchase order.

4. What is the typical lead time for a custom configuration?
Standard models ship in 810 semanas. Custom configurations (p.ej., specific deck angles, special materials) require 1216 semanas. We offer expedited production for an additional 15% fee, reducing lead time to 6 semanas.

5. How do I change the cut point for a different product specification?
Cut points are changed by swapping the polyurethane screen panels. A 2man crew can change a full deck in under 45 minutos. We stock over 50 standard opening sizes (0.5mm to 100mm) for immediate shipment.

6. What is the expected annual maintenance cost?
Annual maintenance costs average $4,000 $6,000. This includes bearing grease (every 40 horas), polyurethane panel replacement (every 1824 meses), and exciter gearbox oil changes (every 2,000 horas). The automatic lubrication system reduces labor costs by 60%.

7. ¿Ofrecen garantías de rendimiento??
Sí. We guarantee a minimum screening efficiency of 90% for your specified cut point (based on a representative material sample). If the unit fails to meet this benchmark after commissioning, we will adjust the stroke, ángulo, or deck configuration at no cost.