1. PAINPOINT DRIVEN OPENING

Is your coke handling operation plagued by persistent inefficiency and hidden costs? For plant managers and engineering contractors, the screening phase is a critical bottleneck with direct consequences for profitability. Common challenges include:

Excessive Fines Generation: Inefficient screening leads to overbreaking of coke, converting valuable product into lowvalue fines. This represents a direct loss of revenue per ton.
Frequent Screen Clogging & Downtime: Sticky coke particles and moisture cause blinding, requiring frequent shutdowns for manual cleaning. This unplanned downtime halts your entire processing line.
Inconsistent Product Grading: An unreliable screen fails to deliver precise size separation, compromising the quality specifications demanded by your blast furnace or foundry customers, risking contract compliance.
High Maintenance & Replacement Costs: Vibrating screens that are not engineered for the abrasive nature of coke suffer rapid wear on decks, springs, and exciters, leading to high spare part consumption and labor costs.

Are you ready to reduce your costperton, increase plant availability, and ensure a consistently onspec product? The solution lies in specifying a purposebuilt Coke Vibration Screen.

2. PRODUCT OVERVIEW

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the dry separation of metallurgical coke into precise size fractions after crushing. Its core function is to ensure only correctly sized coke proceeds to blast furnace charging or shipment.

Operational Workflow:
1. Feed Introduction: Crushed coke is uniformly fed onto the inclined screen deck(s) via a feed box or chute.
2. Vibratory Separation: Highintensity, linear or circular vibration stratifies the material. Smaller particles pass through the screen media apertures (undersize), while larger particles travel across the deck surface (oversize).
3. Product Diversion: Separated fractions are discharged via distinct chutes—typically into oversize (return for recrush), product size, and fines hoppers.

Application Scope: Primary sizing of metallurgical coke in coke plants, steel mills, and bulk handling terminals. Suitable for hot or cold coke screening.

Key Limitations: Not designed for wet screening processes or for materials with extreme adhesive properties without specialized deck treatments.

3. CORE FEATURES

HeavyDuty Deck System | Technical Basis: Modular, hightensile steel frame with replaceable wear liners | Operational Benefit: Withstands continuous impact from large coke pieces; individual panels can be replaced without changing entire deck structure | ROI Impact: Reduces deck replacement costs by up to 60% compared to welded decks

AntiBlinding & WearResistant Screen Media | Technical Basis: Polyurethane or rubberclad wire mesh panels with tensioning system | Operational Benefit: Flexible media surface dislodges sticky particles; superior abrasion resistance maintains accurate aperture size | ROI Impact: Extends media life by 3050%, ensuring consistent product grading and less frequent changeouts

Balanced DualVibrator Mechanism | Technical Basis: Two synchronized eccentric shaft vibrators generating linear motion | Operational Benefit: Provides stable, highGforce vibration for efficient stratification without excessive frame stress; allows adjustable amplitude | ROI Impact: Improves screening efficiency (tonnage per hour) by up to 25% over unbalanced designs, reducing energy per ton processed

DustEncapsulated Vibrator Bearings | Technical Basis: Labyrinth seals with grease purge system in rugged bearing housings | Operational Benefit: Prevents fine coke dust from contaminating bearing grease, the leading cause of vibrator failure | ROI Impact: Dramatically extends bearing service life, often beyond 20,000 hours, minimizing catastrophic drive failures and associated downtime

SubResonant Spring Isolation System | Technical Basis: Lowstiffness coil springs or rubber buffers mounted below the machine's natural frequency | Operational Benefit: Absorbs over 95% of dynamic forces, preventing transmission to the supporting structure | ROI Impact: Eliminates costly structural reinforcement requirements and reduces noise levels for improved site compliance

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (Tonnage/Hr @ Target Size) | Relies on older circular motion or single vibrator designs | Balanced dualvibrator linear motion with optimized deck dynamics| +15% to +25% Increased Throughput |
| Screen Media Operational Life (Abrasion) Standard wire mesh panels Polyurethaneclad tensioned panels +30% to +50% Longer Life |
| Mean Time Between Failure (Vibrator Bearings) ~12,000 hours with standard seals >20,000 hours with advanced dust encapsulation ~+67% Improved Reliability |
| Structural Force Transmission Up to 40% of dynamic force transmitted Subresonant spring isolation absorbs >95% of force ~80% Reduction in Load on Structure |
| Energy Consumption per Ton Processed Higher due to inefficient material travel Optimized kinematics reduce power draw per unit output Up to 18% Lower Energy Cost |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models available from 200 TPH to 1,500 TPH throughput.
Screen Decks: Single or double deck configurations standard; triple deck optional.
Screen Area: From 6 m² to 24 m² per deck.
Drive Power: Dependent on model size; range from 2 x 7.5 kW to 2 x 45 kW vibrator motors.
Vibration Frequency & Amplitude: Typically 7501000 RPM frequency; amplitude adjustable between 48 mm.
Construction Materials: Main frame: heavyduty carbon steel (S355). Wear surfaces: AR400 steel liners. Deck frames: galvanized steel.
Screen Media Options: Highcarbon steel wire mesh (standard), polyurethaneclad mesh (premium), rubber screen decks (special application).
Operating Temperature Range: Designed for ambient to +150°C environments for hot coke applications.
Inclination Angle: Adjustable between 15° 25°.

6. APPLICATION SCENARIOS

Steel Mill Coke Handling Plant Challenge:

A major integrated steel mill faced consistent fines generation exceeding 12%, alongside weekly screen blinding events causing 46 hours of unplanned downtime per occurrence.

Solution:

Replacement of two legacy screens with highcapacity linear motion Coke Vibration Screens featuring antiblinding polyurethane decks and automated lubrication systems.

Results:

Fines generation reduced to below 8%, representing a significant recovery of saleable product grade. Blindingrelated downtime was eliminated for over 14 months postinstallation.

Foundry Coke Producer Challenge:

A merchant foundry coke producer needed stricter adherence to tight size fractions (e.g., 3080 mm) but struggled with inconsistent grading from worn screen decks that stretched over time.

Solution:

Implementation of a doubledeck Coke Vibration Screen with tensioned polyurethane panel media allowing precise aperture control and rapid panel replacement.

Results:

Product consistency improved such that >98% of shipped material fell within specified size ranges yearround. Panel changeout time decreased from two shifts to under four hours.

7. COMMERCIAL CONSIDERATIONS

Our commercial offering is structured around operational scale and required duty level:

Standard Duty Series: For capacities up to 500 TPH in singleshift operations. Includes core features like dual vibrators and basic spring isolation.
Optional Features: Basic dust covers
Service Package: Annual inspection plan
Financing: Standard lease/purchase options

HeavyDuty Series (Recommended for most metallurgical applications): For capacities from 500 TPH – 1200 TPH in continuous operation (>20 hrs/day). Includes all core features plus premium dustencapsulated bearings and AR400 wear liners as standard.
Optional Features: Hotgas deck heating systems (for moist climates), full acoustic enclosures
Service Package: Comprehensive service agreement including predictive vibration analysis
Financing: Tailored project financing available

Pricing is projectspecific based on configuration options such as custom sizes or special materials like stainless steel chutework.

8.FAQ

Q1 Are your Coke Vibration Screens compatible with our existing feed conveyors and discharge chutes?
Our engineering team provides detailed interface drawings during the quotation process based on your required inlet height and discharge points.Custom transition pieces can be supplied if necessary

Q2 What is the expected impact on our overall plant noise levels?
Field data shows our subresonant spring isolation system typically reduces airborne noise emissions by 812 dB(A) compared directly mounted units aiding in workplace health compliance

Q3 How does this equipment address moisturerelated blinding issues?
The combination of high Gforce vibration flexible polyurethane media options allows sticky particles containing residual moisture be ejected effectively For severe cases we offer optional electric or steam heated decks

Q4 What are typical lead times?
For standard HeavyDuty Series models lead time is 1418 weeks from order confirmation Custom configurations may require additional engineering time

Q5 Do you offer performance guarantees?
Yes we provide guaranteed minimum throughput capacity at specified topsize separation based on agreed feed material characteristics These are detailed in commercial contracts