1. PAINPOINT DRIVEN OPENING

Is your coke screening operation plagued by persistent, costly inefficiencies? For plant managers and engineering contractors, the challenges of screening bulk metallurgical coke directly impact throughput, product quality, and bottomline profitability. Common operational hurdles include:

Blinding & Carryover: Fine coke breeze and moisture cause screen mesh blinding, reducing effective screening area. Simultaneously, undersize material carries over with the product stream, contaminating blast furnace feed and degrading its performance.
Excessive Maintenance Downtime: The abrasive nature of coke accelerates wear on screen decks, side plates, and exciters. Frequent component replacement leads to unplanned downtime and high spare parts inventories.
Inefficient Fines Separation: Inadequate separation of the 010mm fraction results in lost revenue from breeze sales and inefficient recycling within the coke plant.
Structural Fatigue & Failure: High Gforces from traditional vibrators transfer damaging stress to the screen body and support structure, leading to weld cracks and catastrophic frame failures.
High Energy Consumption: Inefficient drive systems and oversized motors run continuously, contributing to significant, nonproductive power costs.

Are you seeking a solution that reduces downtime by 30% or more while ensuring consistent product sizing? The answer lies in selecting a coke vibration screen engineered specifically to overcome these materialspecific challenges.

2. PRODUCT OVERVIEW

The equipment in focus is a heavyduty Coke Classification Vibrating Screen, designed for highcapacity sizing of hot or cold metallurgical coke (25mm 80mm) from oven discharge and the subsequent separation of coke breeze (0mm 10mm).

Operational Workflow:
1. Feed & Distribution: Bulk coke is uniformly fed onto the robust feed box, which distributes the material across the full width of the primary screen deck.
2. Primary Sizing: A highstrength wire mesh or punch plate deck performs the primary separation, allowing undersize material (breeze and small fractions) to pass through.
3. Secondary Screening & Fines Removal: A second deck further refines the separation, ensuring maximum recovery of marketable coke breeze.
4. Discharge: Correctly sized foundry or blast furnace coke discharges from the screen end, while separated fines are collected via a dedicated chute for processing or sale.

Application Scope & Limitations:
This equipment is designed for dry or slightly moist coke screening in fixed plant installations. It is not suitable as a replacement for rotary breakers or for handling highly sticky materials without pretreatment. Maximum lump size should not exceed 150% of the nominal top deck aperture.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin, pretensioned panel design with polyurethane side tensioning strips | Operational Benefit: Individual deck sections can be replaced in under 2 hours without welding or specialized tools, minimizing downtime for maintenance. | ROI Impact: Reduces screen cloth changeout time by up to 60%, directly increasing plant availability.

DualMass Drive Technology | Technical Basis: Two synchronized counterrotating masses generating a linear stroke | Operational Benefit: Transfers dynamic forces into the screening motion rather than the support structure; allows for lower horsepower motors due to efficient energy transfer. | ROI Impact: Cuts structural maintenance costs by an estimated 40% and reduces operational energy consumption by 1525%.

AbrasionResistant Lining Package | Technical Basis: Bolton wear plates made from AR400 steel at all critical impact points (feed box, discharge lips) | Operational Benefit: Protects the main screen frame from wear, extending its service life beyond 10 years under typical conditions. | ROI Impact: Eliminates need for frequent frame repair or replacement, providing a predictable longterm asset cost.

Environmental Sealing System | Technical Basis: Multistage labyrinth seals combined with durable rubber dust curtains at transfer points | Operational Benefit: Contains dust emissions at source, improving site environmental compliance and operator health conditions. | ROI Impact: Lowers costs associated with airborne particulate control and reduces housekeeping labor.

Tuned Spring Isolation | Technical Basis: Computermodeled coil spring or rubber shear mount system matched to screen weight and operating frequency | Operational Benefit: Isolates up to 95% of dynamic vibration from the supporting structure, preventing damage to building foundations and adjacent equipment. | ROI Impact: Eliminates secondary structural costs and prevents costly vibrationinduced failures in plant infrastructure.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Deck Panel Replacement Time| 68 hours (welded) | <2 hours (bolted modular) | ~70% faster |
| Structural Fatigue Life| 35 years before major repair| 8+ years with protected frame| >100% increase |
| Screening Efficiency (Breeze Removal)| ~85% efficiency| Consistently >92% efficiency| ~8% more product recovery |
| Operating Noise Level| 95105 dB(A) at 1m| <85 dB(A) at 1m| ~15 dB reduction |
| Annual Power Consumption| Baseline (100%) for same duty| Reduced motor size + efficient drive| 1525% reduction |

5. TECHNICAL SPECIFICATIONS

Capacity Rating: Modeldependent; standard range from 300 MTPH to 1,200 MTPH of bulk coke (bulk density ~0.5 t/m³).
Power Requirements: Driven by dual lowvoltage AC motors (e.g., 2 x 11 kW to 2 x 30 kW), depending on model size and stroke configuration.
Material Specifications:
Frame: Heavyduty carbon steel (S355JR), stressrelieved.
Decks: Options include highcarbon steel wire mesh (65Mn), HARDOX® punch plates, or polyurethane panels.
Wear Protection: AR400 steel liners standard at all impact zones.
Physical Dimensions: Typical singledeck unit footprint ranges from (L)6m x (W)2.5m x (H)1.8m to (L)9m x (W)3.5m x (H)2m.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C; capable of handling hot coke up to ~200°C with appropriate deck material selection.

6. APPLICATION SCENARIOS

Integrated Steel Plant Coke Oven Battery Discharge

Challenge: A major steel producer faced severe blinding on their existing screens due to residual moisture in quenched coke. This caused frequent overloads on downstream crushers and inconsistent blast furnace feed sizing (+/15mm variance).
Solution: Implementation of two parallel heavyduty linear motion Coke Vibration Screens featuring nonblinding balltray decks on the fines removal section.
Results: Screening efficiency stabilized at ≥94%. Oversize contamination was eliminated (<1%), protecting crusher integrity. The consistent product sizing contributed to a documented ~3% improvement in blast furnace burden permeability.

Merchant Coke Producer – Breeze Recovery

Challenge: A merchant plant was losing significant revenue due to poor fines capture; an estimated 810% of saleable breeze was being incorrectly routed back into crusher feed circuits as "circulating load."
Solution: Retrofitting a dedicated Coke Vibration Screen with a finemesh secondary deck into their product classification circuit postcrushing.
Results: Breeze recovery increased from ~82% to over 95%, creating an additional revenue stream exceeding project payback within one year based on market prices for fuelgrade fines.

7.COMMERCIAL CONSIDERATIONS

Our Coke Vibration Screens are offered across three primary tiers:
Standard Duty Series: For capacities up to ~500 MTPH with robust base specifications; ideal for smaller plants or less severe duty cycles.
HeavyDuty Series (>500 MTPH): Our most common specification featuring all core technologies listed above; designed for continuous operation in integrated steel plants.
Custom Engineered Solutions: For unique layouts requiring multiple discharge points specific grades like nut coke separation

Optional features include:
Enclosed designs with integrated dust extraction flanges
Stainless steel components for highly corrosive environments
Advanced condition monitoring sensors
Variable frequency drives

Service packages range from basic commissioning support through comprehensive multiyear maintenance agreements including guaranteed spare parts availability Financing options including leasing are available through our partners

FAQ

What is your typical lead time?

For standard HeavyDuty Series models lead time is typically between weeks depending on current production schedules Custom engineered solutions require additional engineering time

Are your screens compatible with our existing chutes?

Our engineering team will review your existing layout drawings We provide detailed interface specifications including loads connection points ensuring seamless integration into your current transfer system

How do you guarantee performance?

Performance guarantees are based on agreedupon feed material characteristics We provide certified capacity curves based on laboratory testing data Guarantees typically cover throughput capacity under specified conditions

What does commissioning involve?

Our standard package includes supervision installation mechanical alignment initial startup process tuning We ensure correct operation before handover Documentation includes detailed manuals training materials

What are payment terms?

Standard commercial terms involve progress payments tied key milestones Typically % upon order % before shipment balance upon completion satisfactory commissioning Letters credit accepted Financing options available upon request