1. PAINPOINT DRIVEN OPENING

Is your coke handling operation struggling with persistent bottlenecks, excessive fines generation, and unplanned maintenance costs? Inefficient screening directly impacts your bottom line through lost product, increased energy consumption for downstream processes, and costly downtime for screen deck replacements. Are you currently facing:

High Fines Carryover: Ineffective separation leading to valuable coke breeze contaminating the product stream, reducing overall yield and saleable tonnage.
Frequent Screen Blinding & Downtime: Moisture and sticky fines clogging screen apertures, requiring frequent shutdowns for manual cleaning or deck replacement, halting your entire processing line.
Excessive Equipment Wear: Uncontrolled vibration and impact from oversized material or poor feed distribution accelerating wear on screen panels, support structures, and springs.
Inconsistent Product Grading: Fluctuating feed rates or improper screening action resulting in offspec product that fails to meet stringent customer or internal blast furnace specifications.
High Operational Costs: The cumulative effect of these issues—lost production, high maintenance labor costs, and premature component failure—erodes plant profitability.

The solution lies in specifying a vibration screen engineered explicitly for the abrasive, highimpact demands of coke classification. The right equipment transforms these operational challenges into controlled efficiency.

2. PRODUCT OVERVIEW

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the precise size separation of metallurgical coke and coke breeze. Its primary function is to ensure a clean, onspec product while maximizing throughput and minimizing fines loss.

Operational Workflow:
1. Controlled Feed: Sized coke from the crusher or cooler is delivered onto the screen via a regulated feed box to ensure even distribution across the full width of the screening surface.
2. HighIntensity Separation: A robust vibrator assembly (exciters or unbalanced motors) imparts a linear or elliptical motion to the screen box. This action stratifies the material, forcing undersize particles (coke breeze) through the defined screen panel apertures.
3. Positive Material Discharge: Oversize material (product coke) travels along the deck length and discharges at the end of the screen, while undersize material is collected in a hopper beneath the decks for separate conveyance.

Application Scope & Limitations:
This equipment is specifically designed for hot or cold coke sizing in coke handling plants, blast furnace charging systems, and anode production facilities. It is not suitable for wet screening applications without significant modification or for processing materials with drastically different bulk densities and abrasiveness without a full engineering review.

3. CORE FEATURES

HeavyDuty Deck Support System | Technical Basis: Reinforced crossmembers with bolted, modular panel attachment | Operational Benefit: Eliminates panel flexing and fatigue failure under heavy load; allows for rapid, individual panel replacement without welding | ROI Impact: Reduces deck changeout downtime by up to 60% compared to welded systems.
AntiBlinding Deck Technology | Technical Basis: Polyurethane or rubberclad screen panels with flexible, selfcleaning apertures | Operational Benefit: Minimizes adhesion of moist fines; panels flex with each vibration cycle to dislodge trapped particles | ROI Impact: Maintains consistent throughput and grading quality, reducing cleaning shutdown frequency.
DualVibrator Synchronization | Technical Basis: Two externally mounted exciters synchronized via a gear coupling drive | Operational Benefit: Provides stable, linear vibration force across the entire screen box width; allows for easy adjustment of amplitude | ROI Impact: Ensures uniform screening efficiency and extends bearing life through balanced load distribution.
SubResonant Spring Isolation | Technical Basis: Screen box mounted on highcycle composite rubber springs or steel coil springs tuned below resonance frequency | Operational Benefit: Isolates up to 95% of dynamic forces from the supporting structure; allows installation on elevated platforms without major structural reinforcement | ROI Impact: Lowers installation costs and prevents vibration damage to surrounding infrastructure.
AbrasionResistant Lining Package | Technical Basis: Wear plates lined with AR400 steel at all critical impact points (feed box, discharge lips) | Operational Benefit: Protects the main screen body from direct abrasion by coarse coke | ROI Impact: Extends structural life of the main asset by years, deferring major capital expenditure.
Enclosed Dust Sealing System| Technical Basis: Continuous rubber sealing strips between decks and around access doors| Operational Benefit: Contains dust emissions at transfer points for a cleaner, safer working environment| ROI Impact: Reduces housekeeping labor and aids in compliance with plant environmental standards.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Deck Panel Service Life | 36 months (standard steel) | 918 months (modular polyurethane/AR combo) | +100% to +200% |
| Screening Efficiency (for target size)| ~8590% | Consistent 9396% efficiency maintained over time due to antiblinding tech| +5% absolute gain |
| Annual Downtime for Screen Maintenance| 80120 hours/year (cleaning & changes) | 3050 hours/year (modular changes only)| ~60% reduction |
| Vibration Transmission to Structure| Significant; often requires stiffening| Minimal (90% isolation |
| Amplitude Adjustment Process| Requires adding/removing eccentric weights; downtime needed| External adjustment via variable counterweights or motor speed control; operational adjustment possible.| Time savings >75% per adjustment |

5. TECHNICAL SPECIFICATIONS

Capacity & Rating: Designed for throughputs from 50 TPH to 1,200+ TPH depending on model size and aperture selection.
Power Requirements: Driven by dual vibrator motors ranging from 2 x 7.5 kW to 2 x 45 kW (400/690V, 50/60Hz). Drive motor requirements vary by model.
Material Specifications: Main frame Carbon steel (ST37). Wear surfaces Replaceable AR400 steel liners. Screen panels Modular polyurethane rubber tensioned panels OR perforated steel plate panels with abrasionresistant treatment.
Physical Dimensions: Single, double, or tripledeck configurations available. Typical widths from 1.2m to 3.6m; lengths from 4m to 10m inclusive of feed/discharge boxes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Handles material temperatures up to ~150°C continuously with appropriate component specifications.

6. APPLICATION SCENARIOS

Blast Furnace Coke Screening Plant

Challenge A major integrated steel mill experienced excessive fines (<10mm) in their blast furnace feed stock due to degraded screenscreen decks blinding daily through moisture ingress causing inconsistent sizing that risked furnace permeability
Solution Installation of two tripledeck Coke Vibration Screens featuring selfcleaning polyurethane panels on top/middle decks combined with high open area wire mesh bottom decks
Results Achieved consistent product grading with <2% fines carryover eliminated two daily manual cleaning shifts reduced annual maintenance hours by over four hundred

Coke Breeze Recovery Circuit

Challenge An independent coke producer was losing significant revenue as valuable breeze was being misdirected into waste streams due an inefficient singledeck vibrating screen
Solution Implementation of a dedicated doubledeck fine Coke Vibration Screen equipped with specialized ball tray decks prevent blinding on fine mesh apertures
Results Recovered an additional metric tons per hour saleable breeze increasing annual revenue by over fifteen percent achieving full payback within eight months

Anode Grade Coke Sizing

Challenge A carbon plant required extremely tight particle size distribution control but their existing screens produced excessive attrition generating unwanted ultrafines during classification process
Solution Commissioning customengineered lowattrition linear motion Coke Vibration Screens featuring gentle material handling low stroke/highfrequency design combined cascading deck arrangement
Results Reduced generation minus fraction by thirty percent while meeting stringent topsize cut point specification improving downstream paste mixing consistency

COMMERCIAL CONSIDERATIONS

Pricing tiers are primarily determined by machine size deck count features:
Base Model Tier Standard duty construction fixed amplitude vibrators conventional steel panels suitable lower capacity replacement applications
Performance Tier Includes antiblinding decks adjustable amplitude vibrators composite spring isolation extended wear linings recommended new installations major upgrades
Premium Tier Full custom engineering including special materials dust suppression hoods advanced monitoring sensors predictive maintenance integration

Optional Features Include spray systems dust encapsulation covers variable frequency drives remote monitoring kits different panel types access platforms walkways

Service Packages Available as factory commissioning multiyear parts kits annual inspection contracts full maintenance agreements ensuring operational readiness

Financing Options Flexible acquisition models include outright purchase capital lease operating lease structures tailored support project financing large capital projects

FAQ

What is typical lead time delivery new Coke Vibration Screen?
Lead times vary based complexity customization standard designs typically available within weeks fully customized units may require months detailed engineering fabrication commence upon order approval

Can this equipment integrate existing conveyor feed system?
Yes screens are engineered accept standard belt conveyor feeds require properly designed feed box ensure even distribution across full width maximize efficiency prevent localized wear

How does power consumption compare older screening equipment?
Modern designs focus energy efficiency direct drive exciters premium efficiency motors typically result similar marginally lower consumption compared older units while delivering significantly higher throughput reliability

What key factors determining correct screen size my application?
Primary factors are total required tonnage per hour desired separation sizes percentage open area selected panels material bulk characteristics consultation application engineer essential specify correctly

Are spare parts readily available?
Manufacturers maintain comprehensive inventory critical wear parts vibrator assemblies springs panel modules ensuring availability minimize potential extended downtime events