1. PAINPOINT DRIVEN OPENING

Is your coke handling operation losing profitability to inefficient screening? Common challenges with conventional screens directly impact your bottom line. Are you experiencing:
Excessive Product Loss: Fines and valuable coke breeze passing through worn or inefficient screen decks, representing direct revenue loss with every ton processed.
High Maintenance Downtime: Frequent failures of screen decks, bearings, or exciters due to the extreme abrasion and impact of coke, leading to unscheduled stoppages and production delays.
Blinding & Poor Efficiency: Moisture or sticky fines blinding screen meshes, drastically reducing effective screening area and throughput, forcing recirculation and increasing energy costs.
Inconsistent Product Grading: Unreliable particle size separation resulting in offspec product for blast furnace or foundry customers, risking contract penalties and reputational damage.
Structural Integrity Concerns: Constant, highimpact vibration leading to fatigue cracks in the screen body or support structure, creating major safety risks and costly capital repairs.

The core question for plant managers is: how can you achieve precise, reliable coke classification while maximizing uptime and protecting your material yield?

2. PRODUCT OVERVIEW

The Export Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the dry classification of metallurgical coke and coke breeze. Designed for robustness in harsh environments, it separates crushed coke into precise size fractions critical for blast furnace efficiency and other industrial processes.

Operational Workflow:
1. Feed Introduction: Sized coke from crushers is evenly distributed onto the feed box of the vibrating screen.
2. Stratification & Separation: Highintensity, linear or circular vibration stratifies the material bed. Smaller particles descend to contact the screen cloth apertures, while larger particles travel across the deck surface.
3. Size Fraction Discharge: Correctly sized particles pass through the screen mesh (undersize), while oversized particles discharge at the deck end (oversize). Multideck configurations allow for simultaneous separation into several product grades.

Application Scope: Primary and secondary screening of metallurgical coke, coke breeze recovery, sizing for sinter plants, and prescreening for gasification processes.

Limitations: Not designed for wet screening applications or for materials with extreme adhesive properties without specialized deck treatments.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin, subframe mounted polyurethane or rubber clad steel panels | Operational Benefit: Dramatically reduced replacement time; individual panels can be changed without full deck dismantling. | ROI Impact: Cuts planned maintenance downtime by up to 60%, increasing annual operating hours.

HeavyDuty Exciter Assembly | Technical Basis: Internally mounted, greaselubricated vibrator unit with oversized bearings and labyrinth seals | Operational Benefit: Isolated from direct material impact; delivers consistent amplitude under variable load conditions. | ROI Impact: Proven service intervals exceeding 8,000 hours under continuous operation, reducing spare part consumption.

HuckBolted Construction | Technical Basis: Highshear strength fastener system used throughout the main frame and side plates | Operational Benefit: Eliminates weld fatigue failures; creates a rigid, maintenancefree body structure resistant to crack propagation. | ROI Impact: Extends structural service life by years, avoiding premature capital replacement costs.

Tiered Dust Enclosure | Technical Basis: Multisegment rubber skirtboard system with quickrelease clamps at multiple transfer points | Operational Benefit: Contains dust emission at feed, discharge, and side skirts; improves plant environmental compliance. | ROI Impact: Mitigates material loss as airborne fines and reduces housekeeping labor requirements.

Tuned Spring Suspension | Technical Basis: Computermodeled coil spring or rubber buffer system matched to dynamic load parameters | Operational Benefit: Isolates up to 85% of dynamic forces from the supporting structure; allows installation on elevated platforms. | ROI Impact: Eliminates costly structural reinforcement needs during installation and minimizes vibration transmission.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Conventional Screens) | Export Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Deck Panel Lifespan| 36 months with steel wire mesh | 1218 months with polyurethane clad panels | +150% average improvement |
| Annual Availability| ~8590% (including planned stops)| >94% (documented field data) |>4 percentage point gain |
| Screening Efficiency| 8590% on dry 6mm separation| Consistently >94% on same duty| +5% reduction in misplaced fines |
| Energy Consumption per Ton| Baseline (100%)| Optimized drive & mass balance reduces draw by ~15%| 15% lower operational cost |
| Installation & Commissioning Time| 57 days for full assembly on site| Preassembled modules reduce field work to 23 days|<50% of standard time |

5. TECHNICAL SPECIFICATIONS

Capacity / Rating: Model dependent; range from 500 MTPH to 2,500 MTPH of dry coke (bulk density ~0.50.6 t/m³).
Power Requirements: Drive motors from 15 kW to 45 kW per vibrator unit (typically dualdrive), 400/690V AC, IP66 protection standard.
Material Specifications:
Deck Frames & Side Plates: Abrasionresistant steel (AR400/450).
Screen Decks: Modular polyurethane panels with embedded steel reinforcement; optional rubberclad steel or tensioned wire cloth.
Main Frame & Cross Members: Heavywalled structural steel with corrosioninhibiting primer.
Physical Dimensions: Singledeck widths from 1.8m to 3.6m; lengths from 4.8m to 7.2m.
Environmental Operating Range: Ambient temperature from 20°C to +45°C; designed for outdoor installation with appropriate electrical components.

6. APPLICATION SCENARIOS

Integrated Steel Plant Blast Furnace Feed

Challenge A major steel producer faced consistent fines (5mm) contamination in their BFgrade coke (2575mm), affecting furnace permeability and increasing coke rate.
Solution Installation of a primary Export Coke Vibration Screen with two decks following secondary crushing.
Results Achieved a clean +25mm product with less than 3% undersize contamination while recovering 5mm breeze for sinter plant use—a quantifiable reduction of $12/ton in effective BF feed cost.

Merchant Coke Producer

Challenge Offspec product batches due to inconsistent screening after rain events caused moistureinduced blinding on traditional screens.
Solution Implementation of our screens equipped with specialized antiblinding polyurethane decks featuring slotted apertures and balltray cleaning systems.
Results Screening efficiency remained above 92% even with surface moisture up to 7%, eliminating penalty clauses related to product sizing in supply contracts within one quarter.

7 COMMERCIAL CONSIDERATIONS

Export Coke Vibration Screens are offered in three primary tiers:

1. Standard Duty Series: For capacities up to ~800 MTPH. Includes core heavyduty construction features ideal for most merchant coke operations.
2. Heavy Duty Series: For capacities from ~800 MTPH to ~1,800 MTPH featuring enhanced exciter specifications and premiumtier bearing assemblies—the recommended choice for integrated steel plants.
3. Extra Heavy Duty Series: For ultrahighcapacity applications exceeding ~1，800 MTPH， incorporating duplex bearing exciters， reinforced frame design，and premium dust sealing packages．

Optional features include stainless steel fasteners，full stainless steel skirting，integrated spray systems for limited dust suppression，and condition monitoring sensor ports．

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including scheduled inspections，vibration analysis，and guaranteed spare parts availability．Financing options including equipment leasing are available through accredited partners．

FAQ

Q What is the lead time for a typical Export Coke Vibration Screen?
A Lead times vary by model complexity．For standard configurations，expect delivery within X weeks upon order confirmation．Customized solutions may require additional engineering time．

Q Can this equipment integrate into our existing PLCcontrolled plant？
A Yes．All drives are compatible with standard industrial motor starters．The screen itself is supplied readyforsignal connection；it does not include complex control logic but can interface with your plant’s start/stop interlocks．

Q How does this design handle variations in feed rate？
A The exciter system generates a constant force independent of load．While efficiency is optimized at design capacity，field data shows performance degradation remains minimal (±2%) within a ±20% feed rate fluctuation．

Q What are the primary wear items？
A The primary consumables are the modular deck panels followed by wear liners on feed boxes．Spare parts kits based on recommended annual usage are available．

Q Do you provide installation supervision？
A Yes．Professional commissioning supervision is offered as an optional service package．This includes final alignment checks，initial startup assistance，and operator training．

Q Are your technical specifications guaranteed？
A All performance figures stated are based on standard test conditions using defined material characteristics．We provide written performance guarantees as part of our commercial proposal based on your specific application data sheet．

Q What financing structures do you offer？
A We work with thirdparty financial institutions that offer operating leases，capital leases/finance leases,and traditional purchase loans.Structures can be tailored over terms typically ranging from X years