1. PAINPOINT DRIVEN OPENING

Is your coke handling operation facing persistent bottlenecks and escalating costs? The screening stage is often a critical failure point, directly impacting downstream processing and overall plant profitability. Common challenges include:

Blinding & Carryover: Moisture and fine coke particles adhere to screen decks, blinding apertures and forcing material to bypass the screening process. This leads to product contamination, inefficient size separation, and increased wear on crushers.
Excessive Downtime for Maintenance: Frequent breakdowns of vibratory mechanisms, screen cloth changes, and structural fatigue repairs halt your entire production line. Unplanned downtime in a coke plant can cost tens of thousands per hour in lost throughput.
High Energy Consumption & Structural Stress: Inefficient vibration systems draw excessive power while transmitting damaging forces to the support structure. This increases operational costs and creates longterm integrity concerns for the screening station.
Inconsistent Product Grading: Variable feed rates and inefficient screen action result in offspec product. This can lead to rejected loads from steel mill customers or reduced efficiency in anode baking plants.

Are you evaluating a coke vibration screen manufacturer based on initial cost alone, or are you calculating the total cost of ownership—factoring in uptime, maintenance labor, and energy efficiency?

2. PRODUCT OVERVIEW: HeavyDuty Coke Vibrating Screen

This equipment is a highcapacity, linear motion vibrating screen engineered specifically for the abrasive and demanding environment of met coke and petroleum coke sizing. Its design focuses on reliable separation of coke fractions (e.g., blast furnace coke, nut coke, breeze) after crushing.

Operational Workflow:
1. Feed & Distribution: Crushed coke is fed onto the robust feed box, which evenly distributes the material across the full width of the primary screen deck.
2. Positive Material Stratification: A dualshaft vibrator assembly generates a forceful linear motion. This action stratifies the material bed, forcing fines downward to contact the screen media while conveying oversize along the deck.
3. Precise Size Separation: Multiple deck levels (typically 13) equipped with tailored screen panels (wire mesh, polyurethane, or perforated plate) separate the coke into precise size fractions (e.g., +50mm, 50mm+25mm, 25mm).
4. Discharge & Conveyance: Correctly sized fractions are discharged via dedicated chutes onto separate conveyors for stockpiling or direct loading.

Application Scope: Primary and secondary sizing of metallurgical (met) coke and petroleum (pet) coke in steel plants, carbon anode plants, and bulk coke handling terminals.

Limitations: Not designed for sticky materials without predrying or specialized deck treatments. Maximum feed size is limited by deck construction and impact resistance.

3. CORE FEATURES

Modular Deck System | Technical Basis: Independently tensioned panel sections with quickchange clamping | Operational Benefit: Operators can replace worn panels in under 30 minutes per module without specialized tools or cutting torches. | ROI Impact: Reduces screen cloth downtime by up to 70%, increasing annual available operating hours.

Dual CounterRotating Shaft Vibrator | Technical Basis: Two synchronized eccentric shafts generating a linear force vector along the center of mass | Operational Benefit: Provides aggressive material conveyance with minimal vertical force transmission to the support structure. | ROI Impact: Lowers structural reinforcement costs by up to 40% and reduces bearing stress for longer service intervals.

HeavyDuty Side Plates & Cross Members | Technical Basis: Finite Element Analysis (FEA)optimized steel fabrications with continuous welds | Operational Benefit: Withstands constant highimpact loading from large coke lumps without cracking or fatigue failure over a 10+ year design life. | ROI Impact: Eliminates costly side plate replacement cycles every 23 years common in lighterduty screens.

DustEncapsulated Bearing Assembly | Technical Basis: Labyrinth seals combined with positivepressure purge nipples (optional) | Operational Benefit: Prevents abrasive coke dust from contaminating vibrator bearings, the most common cause of catastrophic drive failure. | ROI Impact: Extends bearing service life by an average of 300%, preventing unplanned stoppages exceeding $15k per incident.

Variable Frequency Drive (VFD) Compatibility | Technical Basis: Standardized motor mounts and dynamically balanced vibrator assembly for variable speed operation | Operational Benefit: Allows operators to finetune amplitude/frequency for optimal efficiency with varying feed rates or moisture content from a central control room.| ROI Impact: Optimizes power draw and screening efficiency; field data shows typical energy savings of 1525% versus fixedspeed screens.

AbrasionResistant Lining Package | Technical Basis: Bolton wear liners at all impact points made from AR400 steel or equivalent composite materials | Operational Benefit: Protects critical structural components from direct abrasion, preserving structural integrity.| ROI Impact: Converts potential major structural repairs into simple liner replacements at 20% of the cost.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for Coke Screens | Our Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Deck Panel ChangeOut Time| 48 hours per deck (full weld/bolt) | <2 hours per deck (modular clamp system)| Up to 75% faster |
| Vibrator Bearing Life (L10)| ~8,000 12,000 operating hours| 24,000+ operating hours (with proper sealing)| ~100200% longer |
| Structural Fatigue Life| Designed for ~60 million stress cycles| FEAoptimized for >100 million stress cycles| ~67% longer design life |
| Screening Efficiency (6mm separation)| Typically 8590% under ideal conditions| Consistently achieves 9295% efficiency in field tests| ~58% absolute improvement |
| Transmitted Dynamic Force| High dynamic load factor requiring heavy supports| Low dynamic force design via balanced mass system| Up to 35% less force transmitted |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Modeldependent; standard units handle from 200 MTPH to over 2,500 MTPH of dry crushed coke.
Screen Deck Configuration: Single, double, or tripledeck options; standard widths from 1.5m to 3m; lengths from 4m to over 9m.
Drive & Power: Dual shaft vibrator driven by twin TEFC motors via Vbelts. Total installed power ranges from 15 kW to 75 kW depending on size/mass.
Vibration Characteristics: Linear stroke typically adjustable between 8mm – 11mm; frequency range of 750 1000 RPM.
Material Specifications: Main frame constructed from S355JR structural steel; side plates are often thickergrade S355J2G3; wear surfaces lined with AR400 steel; highstrength alloy steel shafts.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; capable of handling material temperatures up to 150°C with specific seal/bearing configurations.

6. APPLICATION SCENARIOS

Steel Plant Blast Furnace Feed Preparation

Challenge: A major integrated steel mill experienced chronic blinding on their secondary coke screens due to seasonal moisture increases. This caused excessive 10mm fines ("breeze") reporting to the BF skip fraction (>12%), disrupting furnace permeability.
Solution: Installation of two tripledeck linear motion screens featuring nonblinding polyurethane deck panels on lower decks combined with heated deck technology on top decks.
Results: Screening efficiency for 10mm removal improved from 84% to 96%. Fines content in BF feed stabilized below 5%, contributing to an estimated 2% reduction in specific coke rate within six months.

Petroleum Coke Calcining Plant

Challenge: An anodegrade calciner needed precise sizing (30mm+15mm) of green petroleum coke but faced rapid wear of wire mesh panels every three weeks due to extreme abrasiveness.
Solution: Implementation of customdesigned vibrating screens using modular tensioned polyurethane panel systems with ultrahigh abrasion resistance ratings.
Results Screen panel life extended from three weeks to over fourteen weeks between changes Annual maintenance costs for screen media fell by approximately $65k per unit

Bulk Coke Handling Terminal

Challenge A transshipment terminal required highcapacity screening (>2200 MTPH) but had strict limitations on allowable dynamic load transferred into their existing elevated gallery structure
Solution Engineers specified low dynamic force linear motion screens incorporating outofbalance motors configured specifically for force cancellation
Results Required throughput was achieved while transmitted dynamic forces were measured at 28 below the gallery s design limits eliminating need for costly structural reinforcement

Commercial Considerations

Pricing Tiers:
Tier I Standard Duty Units For capacities 1500 MTPH severe duty environments custom materials Quoted per project

Optional Features:
Heated Screen Decks spray bars antiblinding systems
Advanced Sealing Packages including positive air purge systems
Full Stainless Steel Construction contact parts specific corrosion environments
Integrated Condition Monitoring Systems vibration temperature sensors

Service Packages:
Basic Package Standard warranty parts manual
Platinum Support Package Extended warranty priority parts dispatch annual health inspection reports
Full Service Contract Includes all scheduled maintenance parts labor performance audits fixed annual fee

Financing Options:
Capital Purchase Direct sale outright ownership
Lease To Own Programs Fixed term lease concluding transfer title suitable managing capital expenditure
Operating Lease Lower monthly payments equipment returned end term

FAQ

What if my existing feed chutes support structure don align perfectly with your standard dimensions We provide comprehensive interface drawings during quotation phase can manufacture custom adapter sections transition pieces ensure fit within your current layout at minimal additional cost

How does this screen handle wet sticky coke during rainy seasons While no vibrating screen eliminates all sticky material issues our combination open deck designs optional heated decks significantly reduces adhesion For severe conditions we recommend pre drying steps consult our engineering team specific recommendations

What is realistic expected lifespan main frame structure before major refurbishment Based operational history similar installations our FEA optimized frames show no signs fatigue cracking requiring repair years proper installation maintenance Bearings seals consumable components will require scheduled replacement

Can you supply compatible replacement screen panels our existing competitor s equipment Yes we manufacture tailor made tensioned modular panels fit most major OEM brands often higher wear resistant materials than original specification Provide model number detailed measurements quotation

Do you offer performance guarantees Field data allows us confidently guarantee screening efficiency percentage points specific cut size provided agreed upon consistent feed rate material characteristics Guarantees outlined detail commercial contract

What typical delivery lead time after order confirmation For Tier II heavy duty units standard configuration lead time ranges weeks depending current workload Tier III custom solutions require detailed engineering lead times start weeks Final schedules confirmed upon order

Are installation supervision commissioning services included Basic installation manuals detailed General Arrangement drawings included Optional site supervision commissioning engineer services available fixed daily rate ensure optimal startup performance