1. PAINPOINT DRIVEN OPENING

Is your coke screening operation plagued by persistent, costly inefficiencies? For plant managers and engineering contractors, the vibration screen is a critical yet vulnerable point in the material handling chain. Common challenges include:

Excessive Downtime: Premature screen deck failure and bearing seizures due to coke abrasiveness and high temperatures, leading to unplanned maintenance stops that cost thousands per hour in lost production.
Poor Separation Efficiency: Inconsistent sizing of metallurgical coke or petroleum coke, resulting in offspec product that fails to meet blast furnace or anode grade requirements, directly impacting your revenue and customer contracts.
High Maintenance Costs: The constant battle against wear on screen panels, side plates, and exciters creates a relentless cycle of parts replacement and labor expenditure.
Structural Integrity Risks: Fatigue cracks in the screen body from relentless, highcycle loading threaten catastrophic failure, posing safety risks and requiring major capital repair.

Are you searching for a vibration screen engineered not just to handle coke, but to withstand its punishing demands while protecting your bottom line?

2. PRODUCT OVERVIEW: HeavyDuty Coke Vibration Screen

This equipment is a specifically engineered linear motion or elliptical motion vibrating screen for the classification and sizing of hot or cold metallurgical coke and petroleum coke (calcined or green). Its design prioritizes durability, uptime, and precise separation under severe operating conditions.

Operational Workflow:
1. Feed & Distribution: Bulk coke from the crusher or oven is evenly distributed across the full width of the feed deck via an integral feed box.
2. Stratification & Sizing: Controlled vibratory motion stratifies material by size; undersize particles pass through precisely sized screen panel apertures.
3. Material Conveyance: Larger particles travel along the deck length for discharge as oversize product.
4. Product Separation: Properly sized fractions are collected via sealed discharge spouts for downstream processing or shipment.

Application Scope: Primary and secondary screening of metallurgical coke (blast furnace coke), petroleum coke (anode grade, fuel grade), recarburizers. Suitable for hot screening applications postquenching (with appropriate material specs).
Limitations: Not designed for wet screening processes or as a replacement for scalping screens handling extremely large (+300mm) feed with high impact loads without prior modification.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin, interchangeable panel design with multiple wear materials | Operational Benefit: Operators can replace individual worn panels in under 30 minutes without welding or major dismantling. | ROI Impact: Reduces deck changeout downtime by up to 70% versus welded systems.

HighTemperature Bearing Assembly | Technical Basis: Labyrinth seals with hightemp grease purging and forcedair cooling jackets | Operational Benefit: Maintains bearing integrity when screening hot coke up to 200°C, extending lubrication intervals. | ROI Impact: Field data shows a 40% increase in mean time between failures (MTBF) for bearing assemblies.

DualWall Side Plate Construction | Technical Basis: Reinforced boxsection design with internal ribbing | Operational Benefit: Eliminates stress concentration points that lead to fatigue cracking under heavy cyclic loads. | ROI Impact: Virtually eliminates unscheduled downtime from structural body repairs over the machine's lifespan.

Precision Tensioning System | Technical Basis: Hydraulic or advanced manual tensioning wedges for polyurethane or wire mesh panels | Operational Benefit: Ensures uniform panel tension across the entire deck area, preventing premature loosening and blinding. | ROI Impact: Improves screening efficiency consistency by up to 15% and extends panel life.

DustContainment Design | Technical Basis: Integrated skirt boards, sealed discharge spouts, and optional negative pressure connections | Operational Benefit: Significantly reduces airborne particulate emissions at transfer points. | ROI Impact: Lowers housekeeping costs and facilitates compliance with plant environmental standards.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Our Coke Vibration Screen Solution | Documented Advantage |
| : | : | : | : |
| Screen Panel Lifespan (Abrasive Coke) | 46 Months (Welded Steel) | 812 Months (Modular PU/Alloy) | +100% Improvement |
| Annual BearingRelated Stops | 34 Events/Year | ≤1 Event/Year (with recommended protocol) | ~75% Reduction |
| Screening Efficiency Consistency (for 25mm +5mm cut) | ±8% Variance over campaign life| ±3% Variance over campaign life| Improved Consistency |
| Total Cost of Ownership (5Year Period) Based on parts/labor/downtime| Baseline (100%)| Estimated 6070% of Baseline| 3040% Reduction |

5. TECHNICAL SPECIFICATIONS

Capacity & Rating: Modeldependent; standard range from 500 to 2,500 tonnes per hour of dry coke bulk density (~0.50.8 t/m³).
Drive & Power: Dualshaft eccentric vibrator assembly; Motor power from 15 kW to 75 kW depending on size and dynamics.
Material Specifications:
Deck Frames & Side Plates: Highyield strength carbon steel (Q345B equivalent or higher).
Wear Liners & Deck Modules: Options include AR400 steel abrasion plate, tensioned polyurethane panels with steel reinforcement, or rubberclad panels.
Springs: Heavyduty helical steel springs or rubber shear springs rated for high static load.
Physical Dimensions: Single, double, or tripledeck configurations; widths from 1.5m to 3m; lengths from 4m to 8m.
Environmental Operating Range: Ambient temperature operation from 20°C to +50°C; capable of handling material temperatures up to 200°C with specified configurations.

6. APPLICATION SCENARIOS

[Steel Plant Blast Furnace Feed] Challenge: A major integrated steelmaker experienced frequent wire mesh panel blowouts on hot coke screens (~150°C), causing excessive spillage and plant outages every 1012 weeks.Solution Implementation: Installation of a heavyduty coke vibration screen featuring modular polyurethane/steel hybrid panels with a precision hydraulic tensioning system.Results: Panel changeout intervals extended to over 32 weeks; screening efficiency for critical 50mm+25mm fraction stabilized at >94%; annual maintenance hours reduced by an estimated 320.

[Calcined Petroleum Coke Plant] Challenge: An anodegrade CPC producer faced severe dust emission at screen transfer points and rapid wear from highly abrasive calcined material.Solution Implementation: Deployment of a fully enclosed vibrating screen with dualwall side plates, internal dust skirts, and AR400 lined modular decks.Results: Captured dust emissions reduced by an estimated >90% at source; deck lifespan increased from ~5 months to over 10 months; product purity improved due to contained environment.

7. COMMERCIAL CONSIDERATIONS

Our heavyduty coke vibration screens are offered in three primary tiers:

1. Standard Duty Series: For less severe applications/cold coke screening; competitive capital cost focus.
2. Premium Duty Series (Most Common): Includes all core features outlined above; optimized for total cost of ownership.
3. Custom Engineered Series: For extreme capacity, temperature (>200°C), or unique footprint requirements.

Optional Features & Upgrades: Aircooled bearing housings, explosionproof motors for specific environments online condition monitoring sensors (vibration/temperature), special coatings.

Service Packages:

Basic Warranty
Extended Performance Guarantee with prescribed maintenance
Annual Inspection & Parts Kitting Program
Turnkey Installation & Commissioning Supervision

Financing options including equipment leasing and milestonebased payment plans are available through our partners to facilitate capital expenditure planning.

8.FAQ

1.Q What is the lead time for a standard model?
A.For common Premium Duty Series models in standard widths lead time is typically XX weeks upon final engineering approval

2.Q Are your screens compatible with our existing foundation structure?
A.We provide complete foundation load data Our engineering team can assess your current pedestals Typically our designs aim for compatibility but minor reinforcement may be advised

3.Q How does this design address blinding when processing sticky green petroleum?
A.We specify nonblinding polyurethane panel profiles with tapered openings combined with our high Gforce vibratory motion which field data shows reduces adhesionrelated blinding significantly compared traditional flat wire decks

4.Q What is the expected power consumption versus older screens?
A.Due efficient vibrator design modern bearings energy consumption often decreases despite robust construction Specific kW ratings provided technical specs allow direct comparison

5.Q Do you offer wear package pricing?
A Yes We offer guaranteed annual operating cost contracts which bundle expected wear parts deck modules seals into fixed annual payment simplifying budget forecasting

6.Q Can you assist retrofit into existing building constraints?
A Yes Our standard designs can modified accommodate limited headroom discharge height requirements while maintaining performance parameters

7.Q What operational training provided?
A We supply detailed operation maintenance manuals plus onsite training covering startup/shutdown procedures daily checks tensioning protocols troubleshooting