1. PAINPOINT DRIVEN OPENING

Is your coke processing line plagued by persistent bottlenecks and escalating operational costs? For plant managers and engineering contractors, the screening phase is often a critical failure point. Common challenges include:

Blinding & Poor Separation: Fine, moist coke particles adhere to screen decks, causing rapid blinding. This forces either frequent manual cleaning or the acceptance of contaminated product streams, directly impacting product quality and saleable tonnage.
Excessive Downtime for Maintenance: Conventional screens require frequent shutdowns for screen cloth changes and bearing inspections. This unplanned downtime halts your entire processing line, costing thousands per hour in lost production.
High Energy Consumption & Structural Stress: Inefficient vibratory motion translates to wasted electrical power. Furthermore, unbalanced forces can cause premature fatigue and cracking in the screen body and support structure, leading to catastrophic failures.
Inconsistent Grade Control: Inability to maintain precise cut points results in offspec material—either oversized contaminants in the final product or valuable onspec coke reporting to waste.

Are you searching for a screening solution that delivers sustained throughput, minimizes unscheduled stops, and protects your profit margins? The right industrial vibration screen is not just a piece of equipment; it is a strategic investment in plant reliability.

2. PRODUCT OVERVIEW

The HeavyDuty Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the rigorous dry or slightly moist separation of metallurgical coke and petroleum coke. It is designed to handle abrasive materials at high temperatures with continuous 24/7 operation.

Operational Workflow:
1. Feed & Distribution: Sized coke from crushers or ovens is evenly distributed across the full width of the screen's feed box.
2. Stratification & Separation: Twin counterrotating vibratory motors generate a linear throwing motion, stratifying material. Smaller particles pass through precisely sized screen panel apertures.
3. Discharge: Correctly sized fractions are discharged via separate chutes—typically oversize (for recrushing), product size, and fines.

Application Scope: Primary sizing (scalping) and final grade separation of coke ranging from lump (e.g., +50mm) to nut coke (e.g., 1025mm). Suitable for sinter plants, blast furnace charging systems, and anodegrade coke preparation.

Limitations: Not designed for wet washing applications or for materials with extreme adhesive properties without specialized screen media.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin, pretensioned polyurethane or steel panel sections | Operational Benefit: Reduces media change time by up to 60% compared to woven wire systems. Individual sections can be replaced without dismantling adjacent decks. | ROI Impact: Cuts labor costs for maintenance and increases annual available production time.

Dual CounterRotating Motor Drive | Technical Basis: Two synchronized vibratory motors generating a linear force vector | Operational Benefit: Provides consistent material travel speed and stratification with minimal transmitted dynamic loads to the support structure. | ROI Impact: Lowers structural maintenance costs and ensures predictable screening efficiency for consistent product quality.

Fully Sealed Dust Guard System | Technical Basis: Multipoint rubber sealing between side plates and deck frames | Operational Benefit: Contains dust emission at transfer points, improving site environmental compliance and operator health. | ROI Impact: Reduces risk of regulatory fines and housekeeping labor while protecting downstream equipment from abrasive dust ingress.

HighStress Frame Design | Technical Basis: Reinforced side plates with internal crossbracing and stressrelieved welds | Operational Benefit: Withstands cyclic loading over extended service life, preventing frame cracking—a common failure point in demanding coke screening. | ROI Impact: Extends major asset lifespan beyond 10 years under severe duty, delaying capital replacement.

Centralized Greasing Labyrinth Bearings | Technical Basis: Bearing housings with labyrinth seals plumbed to a single grease nipple per bearing shaft | Operational Benefit: Enables safe, rapid lubrication during brief operational pauses without disassembly. | ROI Impact: Extends critical bearing service life by ensuring proper lubrication, preventing failures that cause weeklong downtime.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Coke Vibration Screen Solution | Documented Advantage |
| : | : | : | : |
| Screen Media Change Time (Full Deck) | 1624 hours (woven wire) | 68 hours (modular panels) | Up to 67% reduction |
| Bearing Service Life (L10) under heavy load| ~12,000 hours | 18,000+ hours with recommended greasing regime| 50%+ improvement |
| Structural Integrity (Time to first major frame weld repair) | Typically 35 years| Designed for 7+ years before major intervention| >40% longer service interval|
| Screening Efficiency for 6mm fines removal at high moisture (92% efficiency with antiblinding panel options| ~8% increase in product purity|

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in widths from 1.2m to 3.6m; lengths from 4.8m to 10m. Capacities from 150 TPH to over 2000 TPH depending on aperture size and material characteristics.
Drive & Power: Dual vibratory motors ranging from 2 x 7.5 kW to 2 x 55 kW per unit (400V/50Hz or other standards). Total force output adjustable via motor weights.
Deck Configuration: Single, double, or tripledeck layouts based on separation requirements.
Construction Materials: Main frame: S355JR structural steel; Side plates: Hardox® abrasionresistant steel; Screen panels: Polyurethane (Trellex®/Skega® type), punched steel plate, or rubber clad.
Physical Dimensions & Mass: Varies significantly by model; typical installed mass ranges from ~8 tonnes (small) to >35 tonnes (large).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; material temperature handling up to +120°C with heatresistant components.

6. APPLICATION SCENARIOS

[Steel Mill Blast Furnace Feed] Challenge: A major integrated steel mill experienced frequent blinding on its final coke screens before skip charging, causing oversized material (+80mm) to enter the furnace burden at rates exceeding plant specifications (>3%). This disrupted furnace permeability.

[Solution]: Implementation of a tripledeck Coke Vibration Screen equipped with nonblinding rubber screen panels on the top deck for effective scalp removal of oversized pieces.

[Results]: Oversize contamination reduced consistently below <0.8%. Annualized reduction in fuel rate attributed partly to improved burden distribution was measured at approximately ~1%.

[Petroleum Coke Calcining Plant] Challenge: An anodegrade calciner needed precise separation of calcined petroleum coke into multiple fractions (12mm+6mm, 6mm+3mm). Their existing screens suffered rapid wear from abrasion required biweekly shutdowns for cloth changes.

[Solution]: Installation of two parallel doubledeck Coke Vibration Screens fitted with modular polyurethane screen panels rated for high abrasion resistance.

[Results]: Screen panel life extended from two weeks average upto eight weeks between changes resulting in an estimated gain of over two hundred production hours annually per line while maintaining sharp separations

7 COMMERCIAL CONSIDERATIONS

Our Coke Vibration Screens are offered as engineeredtoorder capital equipment

Pricing Tiers:
Standard Duty Series For lower capacity replacement applications
HeavyDuty Series For new installations primary sizing
UltraDuty Series For highest tonnage plants abrasive conditions

Optional features include stainless steel dust covers hotmaterial adaptations special liners online condition monitoring sensors

Service packages range from basic commissioning comprehensive multiyear maintenance agreements including scheduled inspections parts supply priority technical support

Financing options available including leasetoown structures progressive payment plans aligned with project milestones facilitating easier budget allocation

8 FAQ

Q What if my existing foundation cannot support new equipment
A Our engineering team can provide retrofit designs including custom support structures isolators adapt existing feed discharge chutes minimizing civil work costs

Q How does this screen integrate with my current PLC control system
A The vibratory screen operates as standalone machine but can be equipped standard Modbus TCP/IP Profibus interfaces allowing monitoring motor temperature vibration levels central control room

Q What typical lead time delivery
A Lead times vary based complexity configuration Standard HeavyDuty models typically available within weeks fully custom engineered solutions require detailed consultation provide accurate timeline

Q Are spare parts readily available
A We maintain regional inventory critical wear parts modular screen panels motor sets bearing assemblies ensure maximum equipment availability reduce lead times emergency repairs

Q Can you provide performance guarantees
A Yes we offer guaranteed capacity separation efficiency specifications based certified test data your specific material sample processed our laboratory prior order confirmation