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 production halts. Are you facing these challenges?

Sieve Blinding & Downtime: Sticky coke breeze and moisture cause screen mesh clogging, forcing frequent shutdowns for manual cleaning. This can reduce effective screening time by up to 30%, creating a major throughput bottleneck.
Excessive Fines Generation: Aggressive or poorly tuned vibration fractures coke lumps, producing excess undersize material (fines). This degrades product value and can overload conveying systems.
Structural Fatigue & Failure: The abrasive nature of coke and continuous vibratory stress lead to weld cracks, side plate failures, and deck damage. Premature structural repairs are a significant capital expense.
Inconsistent Size Distribution: Inaccurate separation results in offspec product sent to blast furnaces or calcining units, affecting their efficiency and your revenue per ton.
High Maintenance Burden: Traditional screens require constant attention—greasing bearings, adjusting drives, replacing mesh panels—tying up skilled labor on reactive tasks.

The core question is: how can you achieve consistent, highvolume coke classification with greater reliability and lower total cost of ownership?

2. PRODUCT OVERVIEW

Our service provides engineeredtoorder Coke Vibration Screens, also known as coke classifying screens or sizing screens. We are specialist fabricators offering a complete designtoinstallation service for heavyduty vibratory screening solutions tailored to the unique demands of coke handling.

Operational Workflow:
1. Feed Introduction: Runofoven or crushed coke is uniformly fed onto the screen’s inlet section via a chute or feeder.
2. Stratification & Separation: HighGforce vibration stratifies the material. Oversize particles travel across the screen surface while undersize material passes through precisely sized deck apertures.
3. Discharge: Correctly sized fractions are discharged into separate chutes or conveyors for routing to blast furnace bins, calcining units, or byproduct systems.

Application Scope: Primary sizing of metallurgical coke, coke breeze separation, prescreening before crushing, and dedusting applications in coking plants, steel mills, and foundries.

Limitations: Not designed as a replacement for scrubbers or washers where significant cleaning is required. Performance is contingent on proper feed rate control as specified in the design parameters.

3. CORE FEATURES

Modular Deck System | Technical Basis: Independently tensioned, boltin panel frames | Operational Benefit: Allows rapid replacement of individual screen decks (polyurethane, rubber, or woven wire) during planned maintenance without dismantling the entire machine. | ROI Impact: Reduces deck changeout downtime by up to 65%, increasing annual available production hours.

DualVector Vibration Drive | Technical Basis: Two synchronized counterrotating eccentric shafts generating a linear stroke | Operational Benefit: Provides precise control over material travel speed and stratification force for optimal separation efficiency with minimal particle degradation. | ROI Impact: Improves screening accuracy by an average of 15%, reducing offspec product and maximizing saleable tonnage.

StressRelieved Frame Construction | Technical Basis: Postweld heat treatment (PWHT) of main frame components | Operational Benefit: Eliminates internal stresses from welding that lead to crack initiation under cyclic loading. Extends structural service life in highvibration environments. | ROI Impact: Mitigates risk of catastrophic frame failure; field data shows a 40% reduction in major structural repairs over a 10year lifecycle.

Centralized Greasing & Sealed Bearings | Technical Basis: Labyrinth seals with grease purge ports on vibrator bearing housings | Operational Benefit: Enables safe lubrication without disassembly; contaminants are expelled from the bearing chamber. | ROI Impact: Extends critical bearing service life by an estimated 50%, lowering spare parts costs and preventing unscheduled stops from bearing seizure.

Adjustable Slope & Stroke | Technical Basis: Manual adjustment wedges for deck angle and externally adjustable counterweight masses on drive shafts | Operational Benefit: Operators can finetune screen action for different coke moisture levels or size specifications without changing hardware. | ROI Impact: Provides operational flexibility to maintain target throughput across varying feed conditions, ensuring consistent plant output.

AbrasionResistant Lining Package | Technical Basis: Bolton wear plates (AR400/500) at all feed points and impact zones | Operational Benefit: Protects structural steel from direct abrasion by coarse coke lumps at high velocity. | ROI Impact: Replaces sacrificial liners instead of rebuilding the main structure; cuts longterm maintenance material costs by approximately 30%.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Design | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Structural Life (to first major repair)| 47 years under heavy load | 10+ years with PWHT frame design| >40% longer service life |
| Screen Availability (uptime)| ~9294% due to frequent clogging/stops| >96% with antiblinding decks & modular design| ~3% absolute increase |
| Fines Generation Reduction| Baseline – dependent on stroke/feed control| Up to 20% reduction via optimized dualvector drive tuning| Up to 20% less fines produced |
| Deck Panel Replacement Time| Full shift (8 hours) requiring torch work & realignment| <3 hours with boltin modular system| Downtime reduced by over 60% |
| Energy Efficiency (kW per ton screened)| Varies widely with inefficient bruteforce designs| Optimized massanddrive balance reduces required motor power by ~15% for same duty.| Up to 15% lower operating power cost |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Designed for throughputs from 100 TPH to over 2,000 TPH based on model size and deck configuration.
Power Requirements: Driven by standard IE3 efficiency electric motors (15 kW – 75 kW typical), 400/690V AC supply.
Material Specifications: Main frame – S355JR structural steel with PWHT; Wear surfaces – AR400/500 steel liners; Decks – Polyurethane (T70AT85A), Rubber (5570 ShA), or HighCarbon Steel Wire Mesh.
Physical Dimensions: Single, double, or tripledeck configurations available; widths from 1.2m to 3m; lengths from 4m to over 9m depending on separation stages required.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; suitable for outdoor installation with appropriate protection; not rated for explosive atmospheres without additional certification.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feed Preparation

Challenge A major steel producer experienced frequent blinding on their primary coke screens due to seasonal humidity variations. This caused hourly throughput drops of over 20%, threatening blast furnace consistency.
Solution Implementation of our Coke Vibration Screen featuring nonblinding polyurethane decks with slotted apertures and an adjustable highstroke drive mechanism.
Results Screen availability increased from 90% to 96%. Throughput stabilized at design capacity yearround, ensuring reliable furnace feed size distribution.

Merchant Coke Producer – Product Grade Flexibility

Challenge The producer needed greater agility to switch between different customer size specifications (e.g., nut coke vs foundry coke) but changeovers were slow and laborintensive.
Solution A custom tripledeck Coke Vibration Screen was supplied with quickrelease tensioners for all decks and externally adjustable stroke/slope controls.
Results Product grade changeover time reduced from one full shift (8 hours) to under 2 hours directly increasing plant utilization enabling more spot market sales opportunities

Byproduct Recovery Plant – Breeze Separation

Challenge Excessive fines in the recovered breeze stream were compromising briquetting press efficiency leading to high recycle rates and equipment wear
Solution Installation of a dedicated dewatering/dedusting Coke Vibration Screen using fine mesh sandwiched polyurethane panels combined with dualfrequency vibration
Results Fines content (1mm) in the final breeze product was reduced by 18%. Briquette quality improved significantly reducing press maintenance intervals

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is projectspecific based on capacity size requirements materials selection Custom designs typically fall into three tiers:

1 Standard Duty For lowercapacity applications (500 TPH) singledeck configurations using standard materials
2 HeavyDuty Most common tier includes PWHT frames modular decks AR liners dual drives capacities upto 1500 TPH
3 Extra HeavyDuty For highest tonnage (2000+ TPH) severeduty applications includes enhanced structural analysis premium wear packages

Optional Features Include dust enclosures heating systems for deck antiblinding specialized sensor packages monitoring vibration levels

Service Packages Available:
• Extended Warranty Coverage upto five years on main structure
• OnSite Commissioning Supervision
• Planned Maintenance Contracts including annual inspections spare parts kits

Financing Options Capital expenditure can be facilitated through equipment leasing plans or staggered payment structures aligned with project milestones

8 FAQ

Q What existing foundation requirements do your Coke Vibration Screens have?
A Our designs include detailed foundation load drawings specifying dynamic forces They typically require reinforced concrete foundations similar in specification to other major vibratory equipment facilitating retrofit projects

Q How does your screen handle variations in feed moisture content which causes sticking?
A The combination of adjustable Gforce stroke nonblinding deck materials optional deck heating systems allows operators compensate realtime Field data shows effective operation even moisture levels fluctuate between 4%8%

Q Are your screens compatible existing PLC control systems our plant?
A Yes Screens supplied complete local control panel but designed interface plant DCS PLC via standard I O signals motor starters vibration sensors providing operational status alarms

Q What typical delivery lead time customdesigned unit?
A Lead times vary complexity For standard heavyduty designs lead time typically ranges between 1622 weeks receipt order detailed specifications confirmed

Q Do you provide performance guarantees?
A Yes We provide guaranteed capacity screening efficiency based agreedupon feed specifications These backed test data similar installations Guarantees outlined commercial contract

Q Can you assist dismantling removal old screening equipment?
A Yes Our service scope include full turnkey project management covering removal disposal legacy equipment installation commissioning new unit minimize overall site disruption