1. PAINPOINT DRIVEN OPENING

Is your coke handling and screening operation a constant source of bottlenecks, maintenance headaches, and product quality inconsistencies? For plant managers and engineering contractors, the challenges of screening coke are distinct and costly.

Excessive Downtime for Screen Deck Changes: Frequent blinding and wear on traditional screens force lengthy, laborintensive media replacements, halting your entire processing line.
Uncontrolled Fines Generation & Product Degradation: Aggressive vibration or improper screen action can break down coke lumps, creating excess fines that devalue your product and reduce yield.
High Maintenance Costs & Component Fatigue: The abrasive nature of coke accelerates wear on screen decks, springs, and vibrator mechanisms, leading to unpredictable repair cycles and spare parts inventory costs.
Inefficient Separation & Missed Contaminants: Inconsistent material travel or insufficient screening intensity can allow oversized contaminants or undersized fractions to pass, compromising blast furnace feed quality.

Are you evaluating equipment that can extend service intervals, protect product integrity, and deliver a measurable return on investment through sustained throughput? The engineering behind your Coke Vibration Screen is critical to solving these operational challenges.

2. PRODUCT OVERVIEW

The HeavyDuty Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the precise sizing and scalping of metallurgical coke in bulk material handling systems. Its design prioritizes durability and consistent performance in harsh, abrasive environments.

Operational Workflow:
1. Controlled Feed: Coke from a crusher or feed conveyor is evenly distributed across the full width of the screen’s inlet.
2. Linear Stratification & Sizing: Dual counterrotating vibrator motors generate a linear throwing motion. This action stratifies the material bed, allowing finer particles to contact the screen media while conveying larger lumps toward the discharge end.
3. Precise Separation: Sized fractions pass through defined screen deck apertures (typically wire mesh or polyurethane panels) into separate discharge chutes.
4. Efficient Discharge: Correctly sized coke (e.g., blast furnace coke) is discharged as product, while oversize material (e.g., +80mm) or undersize fines (e.g., 25mm) are diverted for recirculation or disposal.

Application Scope: Primary sizing/scalping of metallurgical coke postcrushing; coke breeze separation; dedusting applications.
Limitations: Not designed for sticky or moist materials without pretreatment; maximum feed size is limited by inlet design and deck robustness.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin subframe construction with tensioning rails | Operational Benefit: Enables singledeck replacement in under 4 hours versus full deck overhaul. Reduces downtime by approximately 70% for media changes. | ROI Impact: Direct labor savings and increased plant availability translate to higher annual throughput capacity.

Controlled Linear Vibration | Technical Basis: Synchronized twin outofbalance motors generating a linear stroke at 2545° angle | Operational Benefit: Provides uniform material travel velocity without grinding action, minimizing coke degradation and fines generation. Field data shows a reduction in incidental fines production by up to 15%. | ROI Impact: Preserves product value by maximizing yield of premiumsized fractions.

AbrasionResistant Media Options | Technical Basis: Highcarbon steel wire mesh with hardfacing or modular polyurethane panels | Operational Benefit: Extends operational life of screening surfaces by 35x compared to standard woven wire in coke applications. Reduces frequency of shutdowns for media replacement. | ROI Impact: Lowers consumable parts cost per ton and reduces inventory holding requirements for spare screens.

DustEncapsulated Vibrator Motors | Technical Basis: IP66rated protection with continuous lubrication system | Operational Benefit: Seals critical drive components from pervasive coke dust. Eliminates bearing failures due to contamination, ensuring reliable operation in highdust environments. | ROI Impact: Predictable maintenance scheduling extends motor service life, reducing unexpected driverelated stoppages.

Robust Coil Spring Isolation | Technical Basis: Highcycle fatigueresistant steel coil springs supporting the screen body | Operational Benefit: Isolates over 95% of dynamic forces from the supporting structure. Protects building integrity and prevents vibration transmission to adjacent equipment. | ROI Impact: Eliminates costs associated with structural reinforcement and reduces secondary maintenance issues on surrounding plant infrastructure.

Centralized Greasing Points | Technical Basis: Manifolded lubrication lines to all bearing points on vibrator shafts | Operational Benefit: Allows for safe, rapid routine maintenance without dismantling guards or accessing moving parts during operation intervals between shutdowns.| ROI Impact: Promotes bearing longevity through consistent lubrication, preventing costly premature failures and unscheduled downtime.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Screens) | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screen Media Life (in Coke Sizing) | 2 3 Months | 8 12 Months| +300% |
| Mean Time Between Failures (Vibrator Drive) | ~6,000 Hours| >12,000 Hours| +100% |
| Throughput Consistency (±% from rated capacity)| ±15% Variation| ±5% Variation| +67% More Stable |
| Fines Generation (Incidental subgrade production)| Baseline (100%)| ~85% of Baseline| Reduction of ~15% |
| Downtime for Full Media Changeover| 1216 Hours| <4 Hours per deck| Reduction of ~70% |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: CVR Series; Throughput capacities from 500 MTPH to 2,500 MTPH depending on aperture size and feed gradation.
Screen Decks: Single or double deck configurations available.
Drive System: Twin lowwattage vibration motors; Total installed power range: 15 kW – 45 kW depending on model size.
Vibration Data: Linear stroke adjustable between 811mm; Frequency fixed at ~970 RPM.
Construction Materials: Main frame – heavyduty carbon steel (S355JR). Deck frames – abrasionresistant steel (AR400). Side plates lined with replaceable wear plates.
Screen Media Options: Tensioned highcarbon steel wire mesh (standard), modular polyurethane panels (optional), rubberclad panels (optional).
Isolation System: Multiple heavyduty steel coil springs with rubber buffers.
Physical Dimensions (Typical Model CVR2448): Overall length (~7.5m), width (~3m), height (~2m). Weight approx.: ~12,000 kg.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C; dusttight enclosures standard.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feed Preparation

Challenge: A major steel producer experienced excessive blast furnace fines due to aggressive screening action breaking down coke lumps at their sinter plant feed line. This led to reduced permeability in the BF and higher fuel rates.
Solution: Implementation of a customengineered Coke Vibration Screen with controlled linear stroke technology specifically tuned for lump integrity preservation.
Results: Incidental fines (10mm) generation was reduced by 18%. This improved BF operational stability and delivered an estimated annual fuel cost saving based on improved burden permeability.

Coke Production Facility – Product Classification

Challenge: Postcrushing screening operations were plagued by rapid screen cloth blinding from sticky residual volatiles, requiring weekly shutdowns for cleaning and replacement—costing over 300 hours of lost production annually.
Solution: Installation of a dualdeck Coke Vibration Screen featuring heated deck technology (optional) combined with nonblinding polyurethane screen panels on the primary deck.
Results: Screen blinding was virtually eliminated. Media change intervals extended from weekly to quarterly maintenance cycles reclaiming over 250 hours of production time per year while reducing labor costs associated with frequent changes.

7 COMMERCIAL CONSIDERATIONS

Our Coke Vibration Screens are offered under a tiered pricing model based on size/capacity requirements:

1.Standard Series: For proven applications up to ~1200 MTPH capacity includes base features like steel mesh decks dust encapsulated motors central greasing points
2.Performance Series: For highcapacity demanding operations up includes all Standard features plus optional polyurethane decks reinforced inlet boxes extended warranty coverage
3.Custom Engineered Solutions: For unique layouts extreme capacities integrated heating systems fully automated tensioning devices

Optional Features:
Heated screen decks spray bar systems multiple discharge chutes explosionproof motor ratings variable frequency drives advanced condition monitoring sensors

Service Packages:
Comprehensive packages are available including installation supervision commissioning spare parts kits annual inspection contracts emergency breakdown support

Financing Options:
We work with financial partners offer flexible leasing arrangements milestonebased payment plans tradein programs existing equipment

8 FAQ

Q What level foundation preparation required installation?
A Our screens require substantial concrete foundation designed absorb dynamic loads detailed civil drawings load data provided part purchase ensure correct specification

Q Can this screen handle other materials besides metallurgical coke?
A Yes while optimized abrasive nature lump integrity metallurgical coke same robust construction suitable sizing other minerals like sinter iron ore pellets limestone however optimal performance depends specific material characteristics application review recommended

Q How does your pricing compare cheaper alternatives market?
A Initial capital outlay may higher than lighterduty screens however total cost ownership analysis consistently shows lower due significantly extended component life reduced downtime lower maintenance costs We provide detailed TCO models support investment justification

Q What typical delivery lead time standard model?
A Lead times vary based project complexity current manufacturing schedule Standard models typically available within weeks Custom engineered solutions may require longer detailed schedule provided upon application review

Q Do you offer performance guarantees?
A Yes we guarantee our Coke Vibration Screens will meet agreed upon capacity efficiency specifications outlined our proposal based provided feed material characteristics Guarantees cover mechanical performance not consumable wear items like screen media

Q Are your screens compatible existing PLC control systems?
A Yes screens supplied complete local control panel can integrated into plantwide PLC systems via standard interfaces Hardwired signals remote start/stop fault monitoring standard provision Modbus TCP/IP Profinet communication optional