1. PAINPOINT DRIVEN OPENING

Is your coke handling operation plagued by inconsistent product quality, excessive fines generation, and unplanned maintenance halts? For plant managers overseeing coke screening, common challenges directly impact profitability and throughput. Are you experiencing:

Blinding & Carryover: Moisture or sticky fines blinding screen decks, causing product contamination and forcing premature shutdowns for manual cleaning.
Excessive Downtime: Frequent bearing failures or structural fatigue on vibrating screens leading to 2040 hours of unscheduled downtime annually for repairs and parts replacement.
High Maintenance Costs: The abrasive nature of coke accelerating wear on screen panels, decks, and exciters, resulting in high consumable costs and labor for changeouts.
Inefficient Sizing: Inconsistent feed rates or improper vibration dynamics producing offspec material, leading to customer rejections or reprocessing costs.

The core question is: how can you achieve precise, reliable coke classification while maximizing equipment uptime and minimizing total cost of ownership? The answer lies in selecting a purposeengineered 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—typically nut coke, breeze, and lump coke—after the quenching process. Its robust construction handles highly abrasive materials while resisting corrosion from residual moisture.

Operational Workflow:
1. Controlled Feed: Quenched coke is conveyed onto the screen’s feed box, distributing material evenly across the full width of the top deck.
2. HighIntensity Separation: A dualvibrator mechanism imparts a linear or elliptical motion, stratifying material and propelling particles across the screen cloths.
3. Precise Sizing: Oversize material travels across the top deck apertures, while correctly sized particles pass through to lower decks for further fractionation.
4. Discharge & Conveyance: Separated fractions discharge via dedicated chutes onto designated conveyors for stockpiling or direct feed to blast furnaces.

Application Scope & Limitations:
Scope: Ideal for sinter plants, blast furnace charging systems, and foundry operations requiring strict size control (e.g., 2540mm nut coke). Effective for hot or cold coke screening postquenching.
Limitations: Not designed for wet screening processes or as a replacement for scalping screens handling extremely large (+300mm) feedstock without prior crushing. Performance is contingent on proper installation on a structurally adequate support base.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin panel design with side tensioning rails | Operational Benefit: Enables rapid panel changeout (30% faster) by maintenance crews without specialized tools, reducing downtime during wear part replacement. | ROI Impact: Cuts labor hours per changeout by 1520 hours annually.

DustEncapsulated Vibrators | Technical Basis: IP66rated housings with labyrinth seals and continuous lubrication systems | Operational Benefit: Protects critical bearings from coke dust and moisture ingress, the primary cause of premature vibrator failure. | ROI Impact: Extends bearing service life by up to 40%, deferring major vibrator rebuild costs.

AbrasionResistant Lining Package | Technical Basis: Bolton wear plates (AR400 steel) at feed points and discharge lips | Operational Benefit: Shields the main frame structure from direct abrasive impact, preserving structural integrity over a 10+ year lifespan. | ROI Impact: Eliminates costly frame repair or replacement, reducing lifetime capital expenditure.

Tuned Spring Suspension | Technical Basis: Computermodeled coil spring stiffness matched to dynamic load and stroke | Operational Benefit: Isolates 95% of dynamic forces from the support structure, preventing vibration transmission that causes structural fatigue. | ROI Impact: Removes the need for costly reinforced concrete foundations in retrofit applications.

QuickRelease Screen Clamp System | Technical Basis: Rubbercushioned wedgetype tensioning assemblies | Operational Benefit: Allows operators to tension or replace screen cloth sections securely without loose components that can fail. | ROI Impact: Improves screening efficiency consistency by ensuring proper cloth tension, reducing offspec product by an estimated 25%.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime) | 9294% (planned & unplanned downtime) | >96% documented availability | +4% (+350+ operational hours/year) |
| Panel ChangeOut Time (per deck) | 68 hours with welding/grinding required| 93% efficiency maintained| +5% more onspec product |

5. TECHNICAL SPECIFICATIONS

Capacity / Rating: Modeldependent; standard range from 400 to 1,200 tonnes per hour of quenched metallurgical coke.
Power Requirements: Dual vibrator motors totaling 15 kW to 45 kW depending on screen size and stroke requirements; standard supply at 415V/50Hz/3Ph (other voltages available).
Material Specifications: Main frame – heavyduty carbon steel (S355JR). Wear surfaces – AR400 steel liners. Screen decks – hotdip galvanized steel with optional polyurethane or rubberclad panels for extended life.
Physical Dimensions: Typical footprint widths from 1.8m to 3.6m; lengths from 4.8m to 7.2m; weight between 6 and 18 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; handles material temperatures up to ~120°C postquenching.

6. APPLICATION SCENARIOS

[Integrated Steel Plant Blast Furnace Feed] Challenge: A major steel producer faced recurring vibrator failures every 14 months due to dust ingress on their existing screens, causing unpredictable downtime during furnace runs.Solution: Implementation of two highcapacity Coke Vibration Screens with dustencapsulated vibrators and an automated lubrication system.Results: Achieved uninterrupted operation for over 26 months before first scheduled maintenance inspection; screening efficiency improved from ~87% to ~94%, ensuring more consistent blast furnace burden distribution.

[Coke Production Facility Product Quality] Challenge: Offspec fines were contaminating nut coke product due to panel blinding on older screens,Solution: Retrofitting with a new Coke Vibration Screen featuring a quickrelease clamp system that allowed faster switchouts between different aperture profiles.Results: Reduced offspec product generation by an estimated $150k annually in reprocessing costs; panel changeover time decreased by over half during scheduled maintenance windows.

7 COMMERCIAL CONSIDERATIONS

Equipment pricing is tiered based on capacity (tonnes/hour), deck configuration (single vs multideck), and chosen material specifications.

Base Tier includes standard carbon steel construction with polyurethane panels.
Premium Tier upgrades include full AR400 lining packages at highwear points
Optional Features may include:
Dust covers
Spray bars
Condition monitoring sensors
Variable frequency drives

Service packages are available separately:
1.) Onsite commissioning supervision
2.) Annual inspection programs including vibration analysis
3.) Guaranteed spare parts availability programs

Financing options include capital purchase as well as leasetoown structures which can be tailored over terms ranging from three years upwards depending upon local market conditions

8 FAQ

Q1 What are my foundation requirements when installing this Coke Vibration Screen?
A Our tuned spring suspension significantly reduces dynamic loads Field data shows successful installations on properly compacted subfloors without deep piling in retrofit scenarios Detailed civil drawings are provided

Q2 How does this screen handle variations in feed rate which often occur during shift changes?
A The robust design maintains stratification under variable loads up ±20%. For wider fluctuations we recommend pairing it with a surge hopper ahead

Q3 Are your screen panels compatible with other brands’ frames?
A While our modular panels use proprietary clamping rails adaptor kits have been engineered allowing them fit most major OEM frames This provides upgrade path without full machine replacement

Q4 What is lead time typical delivery schedule after order placement?
A Lead times vary based model specification Current standard range between fourteen eighteen weeks exworks Expedited production slots sometimes available subject capacity

Q5 Do you provide performance guarantees?
A Yes we guarantee mechanical performance specifications including capacity under defined conditions These are detailed within commercial proposal alongside acceptance test criteria conducted prior shipment

Q6 Can existing conveyor chutes usually interface directly new unit?
A Our engineering team will review your current layout provide interface drawings Modifications discharge chutes often minimal but should factored into project planning

Q7 What key spare parts should I stock minimize risk operational disruption?
A We recommend holding one set screen panels each deck plus one set vibrator bearings seals This covers most common wear items enables swift corrective maintenance