1. PAINPOINT DRIVEN OPENING

Is your coke handling operation plagued by inconsistent product quality, excessive fines generation, and unplanned maintenance halts? For plant managers overseeing coke screening, common challenges directly impact profitability and throughput:
Product Contamination & Rejections: Inefficient separation allows undersize fines to contaminate blast furnace feedstock or anodegrade product, leading to customer penalties and degraded metallurgical performance.
Premature Screen Deck Failure: The extreme abrasiveness of hot or cold coke accelerates wear on screen panels and support structures, causing frequent, costly replacements and production stoppages.
Blinding & Carryover: Sticky coke particles and moisture can blind screen apertures, while insufficient vibration leads to material carryover, drastically reducing effective screening capacity and classification accuracy.
Structural Fatigue & Vibration Transmission: Poorly engineered vibratory motion transmits damaging harmonics to the base frame and surrounding infrastructure, risking longterm structural integrity.

Are you seeking a screening solution engineered not just to move material, but to precisely classify it while withstanding the punishing environment of coke handling? The right bespoke vibration screen is a capital investment in predictable grading and operational continuity.

2. PRODUCT OVERVIEW

A Bespoke Coke Vibration Screen is a heavyduty industrial screening machine specifically designed for the sizing, scalping, or dedusting of metallurgical coke (cold or hot) and petroleum coke. Engineered from the ground up for this application, it replaces generic screens that fail under abrasive loads.

Operational Workflow:
1. Controlled Feed: Coke is introduced via a regulated feed chute onto the screen’s inlet section, distributing load across the full deck width.
2. HighIntensity Stratification: A precisely tuned vibratory mechanism (typically dual eccentric shaft or bruteforce design) imparts a linear or elliptical motion, aggressively stratifying material. Fines are forced downward to contact the deck.
3. Precise Separation: Stratified particles pass through accurately sized screen panel apertures (wire mesh, polyurethane, or perforated plate), separating into defined size fractions (e.g., +50mm, 50mm+25mm, 25mm).
4. Efficient Discharge: Sized fractions discharge via dedicated chutes into separate collection conveyors or bins for downstream processing.

Application Scope: Primary and secondary screening of metallurgical coke (blast furnace foundry), anodegrade petroleum coke, calcined coke. Suitable for sinter feed preparation and coke breeze recovery.
Limitations: Not designed for wet screening processes or as a replacement for crushers. Maximum feed temperature and particle size are defined by specific material specifications.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin panel subframes with tensioning rails | Operational Benefit: Enables rapid changeover of worn screen media (<4 hours vs. 12+), minimizing downtime for maintenance crews. | ROI Impact: Reduces labor costs per changeout by ~60% and increases annual available production time.

Hot Coke Design Package | Technical Basis: Internal aircooled bearing housings & heatresistant seals | Operational Benefit: Allows continuous operation with coke feed up to 250°C without bearing lubrication failure or seal degradation. | ROI Impact: Eliminates costly cooling periods before screening, increasing line throughput by maintaining process flow.

AntiBlinding & Wear Systems | Technical Basis: Integrated ball tray decks or tensioned wire mesh with polyurethane cleaners | Operational Benefit: Continuous microimpact dislodges sticky particles; wearresistant liners on decks/sideplates extend service life in highabrasion zones. | ROI Impact: Maintains nearoriginal capacity over longer campaigns; reduces consumable parts expenditure by 3040% annually.

Dynamically Tuned Vibratory Frame | Technical Basis: Finite Element Analysis (FEA) optimized stress distribution & isolation spring system | Operational Benefit: Contains vibratory forces within the screen body; minimizes harmful transmission to supporting structures (<90% isolation efficiency). | ROI Impact: Protects civil foundation investments and eliminates ancillary structural repairs.

DustEncapsulated Design | Technical Basis: Gasketed covers & dusttight discharge spouts with inspection ports | Operational Benefit: Contains coke dust at transfer points, improving site air quality and reducing housekeeping labor. | ROI Impact: Lowers environmental compliance risk and reduces cleanuprelated operational delays.

Condition Monitoring Prep | Technical Basis: Preinstalled sensor pads (vibration, temperature) on bearings with external junction box | Operational Benefit: Facilitates easy integration into predictive maintenance programs for early fault detection. | ROI Impact: Prevents catastrophic bearing failures; enables planned shutdowns, avoiding 70+ hours of unplanned downtime per incident.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Screen) | Bespoke Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Deck Panel Service Life| 36 months under abrasive load| 814 months with applicationspecific media| +130% to +150% |
| Screening Efficiency| ~85% for 25mm separation| Consistently >92% for same separation| +8% absolute gain |
| Annual Downtime for Screen Maintenance| 120180 hours (inspections, changes)| 4060 hours (modular design)| 65% reduction |
| Energy Consumption per Ton Screened| Baseline (100%)| Optimized mass & drive efficiency| 15% reduction |
| Bearing MTBF (Mean Time Between Failure)| ~12,000 hours in harsh service| >20,000 hours with cooling/sealing package| +67% improvement |

Screening Efficiency defined as ratio of correctly sized undersize material recovered vs. total undersize in feed.

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Modeldependent; standard range from 200 MTPH to 1,200 MTPH of bulk coke (80 lbs/ft³).
Drive Unit: Dual eccentric shaft mechanism with greaselubricated spherical roller bearings. Alternative bruteforce designs available for highcapacity scalping.
Power Requirements: 15 kW to 55 kW motor (400V/50Hz or as specified), IP66 rated.
Deck Configuration: Single, double, or tripledeck layouts based on cut points.
Screen Media Options: Highcarbon steel wire mesh (hotgalvanized), polyurethane modular panels, perforated manganese steel plates.
Structural Frame: Heavyduty carbon steel plate construction with internal ribbing; shotblasted and coated with industrial epoxy paint system.
Physical Dimensions (Typical DoubleDeck): Length ~7m x Width ~2.5m x Height ~3m (excluding supports).
Operating Environment: Designed for ambient temperatures from 20°C to +50°C; capable of processing material up to 250°C with hot package.

6. APPLICATION SCENARIOS

[Steel Mill Blast Furnace Feed] Challenge: A major integrated steelmaker experienced high variability in blast furnace coke size fraction (50mm+25mm), leading to irregular gas flow and increased fuel rate penalties estimated at €500k annually.Solution: Implementation of a tripledeck bespoke coke vibration screen with precise aperture control ahead of the furnace bins.Results: Achieved consistent sizing with <3% deviation in target fraction; reduced furnace fuel rate by 2%. Payback period was under 18 months via fuel savings alone.

[Petroleum Coke Calcining Plant] Challenge: Anodegrade calciner needed to remove all 8mm fines from final product but faced rapid blinding of standard screens from residual volatiles.Solution: Installation of a bespoke linear motion screen featuring antiblinding ball trays and directheated deck panels.Results: Sustained screening efficiency above 94%; eliminated manual deck cleaning shifts; increased saleable product yield by an estimated 4%.

7. COMMERCIAL CONSIDERATIONS

Our Bespoke Coke Vibration Screens are offered in three primary tiers:
1. (Base Tier): Standard Duty Screens, engineered core components with selectable media options—ideal for lowertonnage operations processing cooled coke.
2. (Recommended Tier): HeavyDuty Performance Screens, includes all core features listed above—the standard solution for most highvolume metallurgical applications requiring reliability.
3. (Premium Tier): SevereDuty Engineered Systems, includes full FEA analysis report customised feed/discharge hoods advanced instrumentation packages—specified for greenfield sites maximum operational data capture

Optional features include variable frequency drives process control integration custom skid bases extended warranty packages

Financing options include capital purchase lease agreements operating leases tailored support service packages provide scheduled inspections parts supply

8.FAQ

Q1 Is your bespoke vibration screen compatible existing conveyor feed hoppers
Our engineering team will review your existing layout interface drawings We design custom inlet transition sections flanges ensure a proper fit minimal retrofit required during installation

Q2 What is typical installation commissioning timeline
From arrival site mechanical installation electrical connection dry run commissioning typically requires days supervised our engineer Delivery lead times vary based specification

Q3 How does this equipment impact overall plant noise levels
Properly installed isolated screens operate within dB(A) range at meter distance meeting typical industrial environmental standards Acoustic enclosures are available option where required

Q4 What are payment terms delivery
Standard terms progress payment upon order confirmation payment prior shipment balance due upon completion Factory Acceptance Test Major projects may qualify structured milestone payments

Q5 Do you provide wear parts ongoing technical support
We maintain comprehensive inventory critical wear parts offer guaranteed hour dispatch key components Support packages include remote diagnostics annual health checks technician dispatches