1. PAINPOINT DRIVEN OPENING

Is your coke handling operation struggling with persistent bottlenecks and hidden costs? The screening stage is often a critical failure point, directly impacting downstream process stability and final product revenue. Common challenges include:

Excessive Fines Generation: Inefficient or aggressive screening action degrades premium coke into lowvalue fines, eroding profit margins with every ton processed.
Unplanned Downtime: Screen deck blinding and premature wear on components like screen cloths lead to frequent, costly stoppages for maintenance and cleaning.
Inconsistent Product Grading: Variability in cutpoint accuracy results in offspec material, causing rejections from blast furnace operators or requiring costly rehandling.
High Operational Costs: Constant component replacement, high energy consumption from inefficient drives, and laborintensive manual clearing directly increase your cost per ton.

Are you seeking a screening solution that prioritizes product integrity, maximizes uptime, and delivers a measurable return on investment? The reliability of your entire coke handling line depends on the performance of this single unit.

2. PRODUCT OVERVIEW

This content details our engineered Coke Vibration Screen solutions, manufactured under contract to the highest specifications for demanding industrial applications. This equipment is a heavyduty linear or elliptical motion vibrating screen designed for the precise sizing and scalping of metallurgical coke and similar carbon products.

Operational Workflow:
1. Feed Introduction: Sized coke from the crusher or coke oven is uniformly fed onto the screen’s inlet section via a conveyor or chute.
2. Stratification & Separation: HighGforce vibration stratifies the material bed. Smaller particles pass through the precisely sized apertures of the screen deck(s), while onsize overs continue across the deck surface.
3. Product Discharge: Correctly sized unders material collects in a hopper below, while overs discharge at the screen’s end, ensuring clean separation into two or more product streams.

Application Scope: Primary sizing (scalping) and final grading of metallurgical coke, recrusher feed preparation, and dedusting operations in coke plants, steel mills, and carbon processing facilities.

Key Limitations: Not designed for sticky materials without specialized deck technology; maximum feed size is constrained by screen design parameters; performance is contingent on correct installation and feed rate control.

3. CORE FEATURES

Our Coke Vibration Screen design incorporates features targeting operational longevity and grading precision.

Modular Deck System | Technical Basis: Independently tensioned, interchangeable panel frames | Operational Benefit: Allows for rapid replacement of individual worn sections without full deck downtime. Different panel types (rubber, polyurethane, woven wire) can be mixed per deck for optimal life. | ROI Impact: Reduces maintenance time by up to 60% per changeout event versus bolteddown systems.
DualMass Drive Technology | Technical Basis: Two synchronized counterrotating masses generating a linear force | Operational Benefit: Delivers consistent stroke regardless of feed load fluctuations; requires lower motor horsepower; transmits minimal dynamic loads to the supporting structure. | ROI Impact: Cuts energy consumption by 1525% compared to bruteforce singlemass designs; reduces structural support costs.
Advanced Sealing & Dust Containment | Technical Basis: Multistage labyrinth seals combined with positivepressure dust skirts | Operational Benefit: Contains fine coke dust at transfer points, protecting bearings and improving plant air quality. | ROI Impact: Extends bearing service life by over 30%, reducing a primary failure point and associated downtime costs.
AbrasionResistant Lining Package | Technical Basis: Bolton wear plates (AR400/500) at all highimpact feed points and discharge lips | Operational Benefit: Protects the main screen body from abrasive wear, preserving structural integrity for decades. | ROI Impact: Eliminates costly body repairs or premature fullunit replacement; defers major capital expenditure.
Tuned Isolation System | Technical Basis: Computermodeled coil spring or rubber shear mount isolators matched to operating weight & frequency | Operational Benefit: Absorbs over 95% of dynamic vibration forces before they reach the support structure. | ROI Impact: Prevents vibrationinduced fatigue cracking in plant infrastructure, avoiding significant civil repair costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Offerings | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screen Cloth Life (Primary Deck) | 24 Months (woven wire) | 69 Months (polyurethane/modular) | +125% average life extension |
| Bearing MTBF (Mean Time Between Failure) | ~12,000 Operating Hours | ~18,000 Operating Hours | +50% improved reliability |
| Energy Consumption per Ton Screened| Baseline (100%)| Optimized Drive & Mass Design| 20% reduction typical |
| Maintenance Downtime per Year| 120180 hours (estimated)| 4070 hours (estimated)| ~65% reduction possible |

5. TECHNICAL SPECIFICATIONS

Specifications are tailored to client throughput requirements; standard models range from:

Capacity / Rating: Designed for throughputs from 200 MTPH to over 1,500 MTPH of dry metallurgical coke (bulk density ~0.5 – 0.7 t/m³).
Power Requirements: Drive motors from 7.5 kW to 45 kW depending on size and Gforce requirement (typically 46 G's), 400/690V AC, 3phase.
Material Specifications: Main frame – carbon steel ST37/44; Wear liners – AR400/500 steel; Deck frames – hotdip galvanized steel; Screen surfaces – polyurethane panels or tensioned wire cloth as specified.
Physical Dimensions: Widths from 1.2m to 3m; lengths from 4m to over 10m (single/triple deck). Total installed weight between ~5t – ~25t.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; suitable for outdoor installation with appropriate protection coatings.

6. APPLICATION SCENARIOS

Steel Mill Coke Handling Plant

Challenge: A major integrated steel mill experienced excessive fines generation (>8% 10mm) during final coke screening before blast furnace charging due to aggressive screen motion degrading fragile coke.
Solution: Implementation of a customengineered Coke Vibration Screen with reduced throw angle polyurethane decks tuned for gentle stratification rather than aggressive throwing action.
Results: Fines generation reduced to below 5%, preserving premium lump coke yield valued at over $180k annually in recovered product revenue.

Independent Carbon Plant Recrusher Feed Prep

Challenge: Frequent blinding of screen decks by moist coke breeze was causing daily operational stoppages for manual rodding at an independent processor.
Solution: Installation of our Coke Vibration Screen featuring nonblinding balltray decks combined with highGforce vibration to ensure continuous cleaning action.
Results: Eliminated daily cleaning downtime (~45 minutes/day), increasing annual available production time by over 250 hours while stabilizing feed consistency to downstream recrushers.

7 COMMERCIAL CONSIDERATIONS

Our contract manufacturing model provides flexibility across project scales:

Pricing Tiers: Based on machine size/throughput capacity:
Standard Duty (1200 MTPH): Customengineered units for greenfield sites or major expansions.

Optional Features: Acoustic hoods/enclosures , spray mist systems , explosionproof motor/drive packages , advanced condition monitoring sensor ports , custom discharge hood configurations .

Service Packages are available separately:
1.Full OEM spare parts provisioning with guaranteed interchangeability .
2.Onsite commissioning supervision & operator training .
3.Preventive maintenance inspection contracts .
4.Fastresponse technical support .

Financing Options can be facilitated through thirdparty industrial equipment finance partners , offering leasetoown structures or term loans that align payments with your project's cash flow timeline .

FAQ

Q1 Are your screens compatible with existing foundations?
A1 Our engineering team provides full foundation load drawings . The tuned isolation system minimizes dynamic loads , often allowing our screens to replace older units on existing foundations after a professional structural review .

Q2 What is the expected impact on my overall plant noise levels?
A2 Field data shows sound pressure levels typically measure between7582 dB(A) at one meter when properly installed . Optional acoustic enclosures can reduce this further if required .

Q3 How do you ensure consistent product quality across manufactured units?
A3 As a contract manufacturer we operate under strict ISOcertified quality management systems . Every Coke Vibration Screen undergoes runin testing prior to shipment , with certified dimensional reports provided .

Q4 What are typical lead times?
A4 Lead times vary by complexity . Standard heavyduty models typically have a lead time of1418 weeks from order approval . Expedited manufacturing slots may be available .

Q5 Can you supply matching conveyors chutes transfer towers ?
A5 Our core expertise is in vibrating screens . We provide detailed interface drawings but recommend working with your preferred bulk handling contractor or we can introduce qualified partners .

Q6 What warranty terms apply?
A6 We provide a standard24month warranty on structural components against defects in materials workmanship Bearings drives motors carry their manufacturers' warranties typically12 months

Q7 Do you offer performance guarantees?
A7 We guarantee mechanical performance build quality throughput capacity based on agreedupon material characteristics Guarantees regarding fines reduction are projectspecific based on pilot test data