Coke Vibration Screen Catalog

Your Screening Challenges Are Costing You More Than You Think

Every ton of coke that passes through your plant carries hidden costs when your screening equipment underperforms. Blinding and clogging of screen decks can reduce throughput by 1525%, forcing unscheduled maintenance stops that cost $5,000$12,000 per hour in lost production. Oversized particles reaching downstream crushers accelerate wear by 3040%, while undersized fines contaminating your product degrade quality and trigger customer rejections. Thermal degradation of screen media in hightemperature coke applications shortens service life by 60% compared to ambient screening. Are your current screens handling the abrasive, hot, and sticky nature of coke without compromising your production targets?

Product Overview: HeavyDuty Coke Vibration Screen

The Coke Vibration Screen is a specialized linearmotion or circularmotion screening system engineered specifically for classifying metallurgical coke, petroleum coke, and calcined coke at temperatures up to 200°C (392°F). This equipment separates coke into commercial fractions (typically +50mm, 2550mm, 1025mm, and 10mm) while rejecting fines and removing oversize material.

Operational Workflow:
1. Feed Introduction: Coke enters via a chute or conveyor at controlled rates (50500 TPH depending on model)
2. Material Stratification: Vibratory motion (68mm amplitude, 8001000 RPM) causes lighter fines to rise and heavier particles to contact the deck
3. Size Separation: Material passes through 24 deck levels with progressively smaller apertures (polyurethane, rubber, or wire mesh panels)
4. Oversize Discharge: +50mm material exits via the top deck discharge spout
5. Fines Collection: 10mm material passes through the bottom deck to a collection conveyor or bin

Application Scope: Primary and secondary screening in coke plants, steel mills, aluminum smelters, and calcining facilities. Limitations: Not suitable for wet coke with >12% moisture content without heated decks; maximum feed temperature 250°C (482°F) with standard components.

Core Features

HighTemperature Deck Construction | Technical Basis: Heattreated 304 stainless steel frame with ceramiclined discharge points | Operational Benefit: Maintains structural integrity at 200°C continuous operation, preventing warping and premature failure | ROI Impact: Extends deck life by 34x versus carbon steel, reducing replacement costs by $8,000$15,000 annually per unit

AntiBlinding Screen Media System | Technical Basis: Selfcleaning polyurethane panels with 45° slotted apertures and ball deck assemblies | Operational Benefit: Reduces screen blinding by 7085% when processing sticky coke fines with 58% moisture content | ROI Impact: Eliminates 23 weekly manual cleaning stops, recovering 812 hours of production time per month

DualShaft Linear Motion Drive | Technical Basis: Two counterrotating vibrator motors with adjustable eccentric weights (610mm stroke range) | Operational Benefit: Provides consistent material conveyance without vertical bouncing, reducing particle degradation by 1520% | ROI Impact: Lowers fines generation by 35%, improving product yield worth $50,000$120,000 annually for a 200 TPH plant

Modular Deck Frame Design | Technical Basis: Bolttogether sectional frames with quickrelease tensioning systems | Operational Benefit: Enables deck replacement in 46 hours versus 1624 hours for welded designs | ROI Impact: Reduces downtime costs by $40,000$80,000 per year based on 4 annual deck changes

Integrated Dust Containment | Technical Basis: Enclosed body with negative pressure ports and labyrinth seals at feed/discharge points | Operational Benefit: Captures 99% of airborne coke dust, meeting OSHA PEL of 0.5 mg/m³ | ROI Impact: Avoids $25,000$50,000 in annual fines and ventilation upgrade costs

Variable Frequency Drive Control | Technical Basis: 060 Hz VFD with programmable start/stop ramps and amplitude presets | Operational Benefit: Allows operators to adjust screening intensity for different coke grades (metallurgical vs. calcined) | ROI Impact: Reduces power consumption by 1825% during partialload operation, saving $3,000$6,000 annually

HeavyDuty Bearing Isolators | Technical Basis: Taconitestyle labyrinth seals with grease purge ports on spherical roller bearings | Operational Benefit: Prevents coke dust ingress, extending bearing life from 6 months to 24+ months | ROI Impact: Eliminates 34 bearing replacement events per year, saving $12,000$18,000 in parts and labor

Competitive Advantages

| Performance Metric | Industry Standard (Conventional Screen) | Coke Vibration Screen Solution | Advantage (% Improvement) |
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| Screening efficiency (at 25mm cut point) | 8288% | 9497% | +1015% |
| Deck replacement interval | 68 months | 1824 months | +200300% |
| Unscheduled downtime (annual hours) | 120180 hours | 3555 hours | 6570% |
| Fines generation (material breakage) | 812% of feed | 47% of feed | 4050% |
| Energy consumption per ton processed | 0.81.2 kWh/ton | 0.50.7 kWh/ton | 3542% |
| Noise level at 1 meter | 9298 dB(A) | 8287 dB(A) | 1012 dB(A) |
| Maximum operating temperature | 120°C (248°F) | 200°C (392°F) | +67% |

Technical Specifications

| Parameter | Model CS1500 | Model CS2000 | Model CS2500 |
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| Capacity (TPH) | 50150 | 100300 | 200500 |
| Screen Area (m²) | 4.5 | 8.0 | 12.5 |
| Number of Decks | 23 | 24 | 34 |
| Motor Power (kW) | 2 x 7.5 | 2 x 15 | 2 x 22 |
| Vibration Frequency (RPM) | 8001000 | 750950 | 700900 |
| Amplitude Range (mm) | 610 | 610 | 610 |
| Feed Temperature Max (°C) | 200 | 200 | 200 |
| Material of Construction | SS304 frame, AR400 wear liners | SS304 frame, AR400 wear liners | SS316 frame, ceramic liners |
| Weight (kg) | 4,200 | 7,800 | 12,500 |
| Dimensions LxWxH (m) | 4.5 x 2.0 x 2.2 | 5.8 x 2.5 x 2.8 | 7.2 x 3.0 x 3.2 |
| Operating Temperature Range | 10°C to 50°C ambient | 10°C to 50°C ambient | 10°C to 50°C ambient |
| Dust Containment | Negative pressure, 500 CFM | Negative pressure, 800 CFM | Negative pressure, 1200 CFM |

Application Scenarios

Steel Mill Coke Screening | Challenge: A 2.5 million ton/year integrated steel mill was experiencing 18% fines generation in their blast furnace coke, increasing coke rate by 12 kg/ton of hot metal and causing permeability issues. Their existing screens required weekly deck changes due to thermal warping. | Solution: Installed two Model CS2000 Coke Vibration Screens with ceramiclined decks and 45° slotted polyurethane panels. Implemented VFD control to reduce amplitude when processing friable coke. | Results: Fines generation reduced to 6.5%, coke rate decreased by 8 kg/ton hot metal, deck replacement interval extended to 22 months, annual maintenance savings of $185,000.

Petroleum Calcining Facility | Challenge: A calcined coke producer was losing 4% of product as 1mm fines due to aggressive screening action. Their circularmotion screens caused particle degradation and generated excessive dust, requiring $40,000/year in baghouse filter replacements. | Solution: Deployed Model CS1500 with linearmotion drive set to 7mm amplitude and 850 RPM. Added ball deck assemblies on the bottom deck for fines removal. | Results: Product yield improved by 3.2%, dust loading reduced by 60%, baghouse filter life extended to 18 months, annual net savings of $320,000.

Aluminum Smelter Anode Plant | Challenge: An anode production facility needed to screen calcined coke at 180°C with 99% efficiency at the 10mm cut point. Their existing screens achieved only 91% efficiency, causing anode quality variations and increased pitch consumption. | Solution: Custom Model CS1500 with heated bottom deck (steam tracing to 150°C) and 0.5mm wire mesh panels with 60° slope. | Results: Screening efficiency at 10mm reached 97.5%, anode rejection rate dropped from 4.2% to 1.1%, pitch consumption reduced by 7%, annual savings of $560,000.

Commercial Considerations

Equipment Pricing Tiers (FOB Factory, USD):

• Model CS1500: $85,000 $115,000 (depending on deck configuration and material options)
• Model CS2000: $145,000 $195,000
• Model CS2500: $225,000 $310,000

Optional Features:

• Heated deck system (steam or electric): $12,000 $28,000
• Ceramiclined feed box and discharge spouts: $8,500 $18,000
• Remote monitoring package (vibration, temperature, bearing condition sensors): $6,500 $14,000
• Dust collection hood with ductwork: $9,000 $22,000
• Spare parts kit (bearings, seals, screen panels for one deck): $4,500 $8,500

Service Packages:

• Standard Warranty: 24 months on structural components, 12 months on vibrator motors
• Extended Warranty (36 months): $8,500 $15,000 per unit
• Preventive Maintenance Program (quarterly inspections, annual bearing replacement): $6,000/year
• Commissioning and Operator Training (3 days onsite): $4,500 plus travel

Financing Options:

• Net 30 terms with approved credit (up to $250,000)
• 12month leasetoown at 4.9% APR (minimum 20% down)
• 36month equipment financing at 6.5% APR through partner lenders
• Tradein program: 1525% credit for qualifying used equipment

FAQ

Q: Can the Coke Vibration Screen handle feed material with varying moisture content?
A: Yes, the screen operates effectively with coke moisture up to 10%. For material exceeding 10% moisture, we recommend the heated deck option (steam or electric) to prevent blinding. Field data shows 94% screening efficiency maintained at 8% moisture versus 82% for standard screens.

Q: What is the typical installation time and foundation requirement?
A: Installation requires 57 days for a standard unit, including alignment, wiring, and commissioning. The foundation must support 1.5x the static weight (dynamic load factor) with isolation springs. A concrete pad of minimum 300mm thickness with anchor bolt template is required. We provide foundation drawings with each order.

Q: How does the Coke Vibration Screen compare to a grizzly feeder for primary coke screening?
A: Grizzly feeders are suitable for +100mm scalping but achieve only 6070% efficiency at smaller cut points. The Coke Vibration Screen provides 9497% efficiency at cut points from 6mm to 75mm. For applications requiring both feeding and screening, we offer an integrated feederscreen combination.

Q: What is the expected service life of screen panels when processing metallurgical coke?
A: Polyurethane panels typically last 814 months with metallurgical coke (hardness 23 Mohs). Wire mesh panels last 48 months. Rubber panels provide 1218 months but have lower open area (35% vs 45% for polyurethane). Panel life depends on feed temperature, with each 10°C above 150°C reducing life by approximately 8%.

Q: Can the screen be retrofitted into an existing screening tower with limited headroom?
A: Yes, the modular deck design allows for custom height configurations. Minimum headroom requirement is 2.8 meters for a 3deck unit. We offer lowprofile versions with 1.8meter height for retrofit applications, though these have 1520% lower capacity per square meter.

Q: What maintenance training do you provide for plant maintenance teams?
A: Our 3day onsite training covers: daily inspection procedures (bearing temperatures, vibration analysis, panel wear measurement), deck replacement techniques (including tensioning specifications), lubrication schedules (grease type and intervals), and troubleshooting common issues (uneven feed distribution, material carryover, noise analysis). Trained teams typically reduce unscheduled downtime by 40% within 3 months.

Q: What is the lead time for a custom Coke Vibration Screen with specific aperture sizes?
A: Standard models ship in 810 weeks from order. Custom configurations (nonstandard widths, special materials, heated decks) require 1216 weeks. We maintain a stock of common screen panel sizes (10mm, 25mm, 50mm slotted) for rapid delivery of replacement parts within 57 business days.