1. PAINPOINT DRIVEN OPENING

Is your coke handling operation plagued by persistent bottlenecks and escalating maintenance costs? For plant managers and engineering contractors, the screening phase is a critical pressure point. Common challenges include:

Blinding & Carryover: Moisture and fine coke breeze adhere to screen decks, blinding apertures and forcing material carryover. This contaminates product grades and necessitates frequent, unproductive stoppages for manual cleaning.
Excessive Deck Wear & Replacement Costs: The abrasive nature of metallurgical coke accelerates wear on screen panels and support structures. Premature failure leads to high parts replacement costs and significant labor expenditure for changeouts.
Structural Fatigue & Vibration Isolation Failures: Inadequate dynamic balancing or isolation can transmit destructive forces to the support structure and building. This results in cracked welds, foundation issues, and collateral damage to surrounding equipment.
Throughput Limitations & Inconsistent Sizing: An undersized or inefficient screen becomes the plant’s bottleneck, limiting overall production capacity. Inconsistent particle separation directly impacts downstream process efficiency and final product quality.

Are you seeking a screening solution that directly addresses these reliability and costperton challenges? The specification of your Coke Vibration Screen is not just an equipment purchase—it’s a decisive factor in your plant’s operational uptime and profitability.

2. PRODUCT OVERVIEW

The HeavyDuty Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the rigorous separation of hot or cold metallurgical coke. Its design focuses on durability, material stratification, and precise size classification in coke oven byproduct plants, blast furnace feed systems, and anodegrade coke processing.

Operational Workflow:
1. Feed & Distribution: Coke feedstock is uniformly introduced onto the robust feed box, which distributes material across the full width of the primary screen deck.
2. Stratification & Separation: The dual eccentric shaft drive assembly generates a forceful linear throwing motion. This action stratifies material, forcing fines downward through defined screen apertures while conveying oversize along the deck length.
3. Sizing & Discharge: Multiple deck configurations (typically 13 decks) allow for precise multifraction separation (e.g., nut coke from breeze). Correctly sized fractions are discharged via dedicated chutes for downstream processing or stockpiling.

Application Scope: Primary sizing of blast furnace coke (2575mm), nut coke separation (1025mm), dedusting of coke breeze (10mm), and scalping of hot coke from ovens.
Key Limitations: Not designed for sticky materials without predrying or specialized deck treatments. Maximum feed temperature typically limited by bearing housing cooling systems and deck material selection.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin, highcarbon steel or hybrid rubber/steel panel design | Operational Benefit: Enables rapid panel replacement (<4 hours vs. 12+ for welded systems) during planned maintenance windows | ROI Impact: Reduces downtime labor costs by ~65% per changeout and extends total deck life up to 40%

Advanced Vibration Isolation | Technical Basis: Multistage isolation with highload coil springs and rubber buffers | Operational Benefit: Absorbs >95% of dynamic forces, preventing transmission to the support structure | ROI Impact: Eliminates costly structural repairs; field data shows a 90% reduction in reported ancillary damage incidents

Forced Lubrication Drive System | Technical Basis: Enclosed gearbox with continuous oil bath lubrication and external cooling loops | Operational Benefit: Maintains optimal operating temperature under continuous, highload conditions in dusty environments | ROI Impact: Extends drive component service life; industry testing demonstrates mean time between failures (MTBF) increased by 300% over greaselubricated systems

Adjustable Eccentric Weight Assembly | Technical Basis: Externally adjustable counterweights on drive shafts | Operational Benefit: Allows finetuning of vibration amplitude (Gforce) to match specific material characteristics (e.g., wet vs. dry coke) without stopping the screen | ROI Impact: Optimizes screening efficiency for varying feed conditions, maintaining target throughput and reducing product grade deviations

AbrasionResistant Lining Package | Technical Basis: Wear plates in feed zone, discharge lips, and side liners fabricated from AR400 steel or equivalent | Operational Benefit: Protects the main frame structure from direct abrasive wear in highimpact zones | ROI Impact: Preserves structural integrity for decades; eliminates need for major frame rebuilds, protecting your capital investment

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Deck Panel ChangeOut Time | 812 hours (welded) | 65% faster |
| Bearing Life (Drive Shaft) | ~12,000 hours | 24,000+ hours with forced lubrication & cooling| >100% longer |
| Structural Force Transmission| 1520% transmitted to base frame| <5% transmitted via multistage isolation| ~75% reduction |
| Screening Efficiency (for 10mm)| ~85% consistent efficiency| 9295% sustained efficiency| ~10% improvement |
| Annual Maintenance Labor Hours| Estimated 80100 hours/year| Estimated 3040 hours/year| ~60% reduction |

_Based on documented field service reports from comparable installations._

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models from 500 to 2,500 tonnes per hour (TPH), sized for specific material density (~0.5 – 0.7 t/m³ for coke).
Drive Power: Electric motor requirements from 15 kW to 45 kW depending on screen size and mass.
Deck Specifications: Up to tripledeck configuration; aperture sizes from 5mm to 80mm; options include punched plate, woven wire mesh, or polyurethane panels.
Material Construction: Main frame heavyduty rolled steel sections with continuous welds; Wear surfaces AR400 steel liners standard; Decks hightensile steel or modular hybrid systems.
Physical Dimensions: Widths from 1.2m to 3.0m; lengths from 4m to 10m; design tailored to headroom constraints.
Environmental Operating Range: Ambient temperature: 20°C to +45°C; Material Temperature: Up to 150°C with heat shields and thermal expansion allowances.

6. APPLICATION SCENARIOS

[Blast Furnace Feed Preparation] | Challenge: A North American steel plant experienced frequent blinding on their primary coke screens during humid months, causing nut coke fraction contamination into the blast furnace burden at a rate of ~8%. This disrupted furnace permeability.| Solution: Replacement with a new Coke Vibration Screen featuring heated deck panels (to reduce moisture adhesion) and an aggressive linear stroke adjustment.| Results: Screening efficiency for the target nut coke fraction stabilized at ≥94%. Contamination fell below 2%, contributing to a documented 5% reduction in blast furnace fuel rate within one quarter postinstallation.

[Coke Breeze Recovery Plant] Challenge:| An anodegrade producer needed higher recovery of fine breeze (6mm) but faced rapid wear on traditional wire mesh decks, requiring monthly replacements that halted the line.| Solution:| Installation of a dedicated singledeck Coke Vibration Screen fitted with tensioned polyurethane screen panels designed for fine abrasion resistance.| Results:| Panel life extended to six months between changes while achieving >90% recovery of target fines. Annual maintenance costs for screening were reduced by an estimated $45k.

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is structured according to capacity rating (TPH) and construction specifications:
Standard Duty Tier: For capacities up to ~800 TPH with standard duty bearings/decks.
Heavy Duty Tier: For capacities up to ~1500 TPH featuring forced lubrication drives/AR400 liners as standard.
Extra Heavy Duty Tier: For capacities exceeding >1500 TPH with full modular decks/extra structural reinforcement.

Optional features include dust encapsulation covers/air seals/hightemperature bearing isolators/motorized angle adjustment/vibration monitoring sensors.

Service packages range from basic commissioning/spare parts kits through annual inspection contracts/full longterm performancebased maintenance agreements.

Financing options are available including straight capital purchase/capital lease/operating lease structures/tailored payment plans aligned with project milestones.

8 FAQ

Q1 Are your screens compatible with existing feed/discharge chutes?
Our engineering team provides detailed interface drawings during quotation All designs account for standard industry layouts We can adapt flanges/support locations as required

Q2 What is typical installation duration?
For a likeforlike replacement installation typically requires fivetoseven days including foundation preparation mechanical setting electrical connection commissioning

Q3 How does this equipment impact my overall plant throughput?
By eliminating blinding maintaining consistent sizing reducing unscheduled stops our screens remove a common bottleneck Field data indicates clients realize full design capacity more consistently often improving overall circuit availability

Q4 What are lead times?
Standard model lead times range eighttotwelve weeks Custom configurations may require twelvetosixteen weeks depending on complexity

Q5 What warranty is provided?
We offer an eighteenmonth warranty on all components excluding normal wear items like deck panels Specific terms are outlined in our commercial proposal

Q6 Can you assist with ongoing technical support?
Yes we provide comprehensive aftersales support including detailed operation manuals remote troubleshooting access prioritized spare parts supply field service technician dispatch

Q7 Do you offer performance guarantees?
Yes we provide guaranteed capacity screening efficiency based on agreedupon feed material specifications These are formalized within our commercial contract