Coke Vibration Screen ODM Manufacturer
1. PAINPOINT DRIVEN OPENING
Is your coke handling operation plagued by persistent bottlenecks, excessive maintenance costs, and inconsistent product quality? For plant managers overseeing coke screening, common challenges directly impact the bottom line:
Blinding & Downtime: Fine, moist coke particles adhere to screen decks, causing rapid blinding. This reduces effective screening area by up to 40%, forcing frequent shutdowns for manual cleaning and slashing throughput.
Premature Wear & High OPEX: The abrasive nature of metallurgical coke accelerates wear on screen panels, decks, and exciters. Unplanned component replacements and associated labor can increase annual maintenance budgets by 25% or more.
Inefficient Fines Separation: Inadequate vibration dynamics lead to poor segregation of breeze (coke fines under 10mm). This results in product contamination, lost revenue from missized material, and potential downstream process issues.
Structural Fatigue & Vibration Transmission: High Gforces needed for effective screening transmit damaging vibrations to the support structure and surrounding equipment, leading to cracks, foundation issues, and safety concerns.
Are you searching for a robust screening solution that delivers consistent uptime, lowers total cost of ownership, and ensures precise size separation for your coke product?
2. PRODUCT OVERVIEW
The Coke Vibration Screen is a heavyduty industrial screening machine engineered for the highcapacity sizing and scalping of metallurgical coke in battery, quenching, and sorting stations. Its core function is to separate crushed coke into precise fractions (e.g., blast furnace coke, nut coke, breeze) while efficiently removing fines.
Operational Workflow:
1. Feed & Distribution: Crushed coke is uniformly fed onto the inlet end of the inclined screen deck via a chute or feeder.
2. Stratification & Separation: Highintensity, linear or elliptical vibration stratifies the material bed. Smaller particles pass through precisely sized deck apertures; oversized particles travel across the deck surface.
3. Discharge: Correctly sized fractions are discharged via separate outlets—oversize to crushers for recirculation or as product, undersize as breeze or product—ensuring a clean separation.
Application Scope: Primary sizing of metallurgical coke after crushing; scalping of oven discharge; dedusting and fines removal; recovery operations.
Limitations: Not designed for sticky materials without specialized deck technology; maximum feed size is constrained by deck opening and machine design; requires controlled feed rate for optimal efficiency.
3. CORE FEATURES
HeavyDuty Deck System | Technical Basis: Modular polyurethane or rubberclad steel panels with reinforced fixing | Operational Benefit: Dramatically increased service life under abrasive conditions; reduced noise levels (by ~10 dBA); panels are easily replaced in sections minimizing downtime | ROI Impact: Cuts panel replacement costs by up to 60% over traditional woven wire decks.
AntiBlinding Technology | Technical Basis: Integrated ball tray decks or ultrasonic screen mesh cleaning systems | Operational Benefit: Continuous microimpact dislodges lodged particles near aperture openings maintaining nearoriginal open area | ROI Impact: Sustains design capacity throughput reduces cleaning downtime by over 70%.
Balanced Elliptical Vibration | Technical Basis: Twin shaft exciter with outofphase synchronized weights generating an elliptical throw pattern | Operational Benefit: Optimized material travel speed with sharp stratification enhances separation accuracy especially for midrange sizes (1030mm) | ROI Impact: Improves product purity by an average of 15% reducing recrush load and maximizing premium fraction yield.
Enclosed DustTight Design | Technical Basis: Gasketed side plates and dust hood connections with integral skirt boards | Operational Benefit: Contains airborne coke dust at transfer points improving site air quality meeting environmental standards | ROI Impact: Lowers housekeeping costs mitigates health safety risks avoids potential regulatory noncompliance fines.
Isolated Vibration Frame | Technical Basis: Dynamic vibration isolators (rubber or spring) between the vibrating body and stationary base frame | Operational Benefit: Absorbs over 95% of dynamic forces preventing transmission to supporting structures eliminates fatigue failures | ROI Impact: Removes need for massive dedicated foundations reduces installation time capital cost protects plant infrastructure integrity.
Centralized Greasing Lube System | Technical Basis: Manifold with lines feeding all major bearing points from a single access port | Operational Benefit: Enables safe rapid lubrication during brief pauses extends bearing life under highload hightemperature conditions | ROI Impact: Standardizes preventive maintenance intervals reduces bearing failure rates by an estimated 40%.
4. COMPETITIVE ADVANTAGES
| Performance Metric | Industry Standard | Coke Vibration Screen Solution | Advantage (% improvement) |
|||||
| Deck Panel Lifespan | Woven wire mesh lasts 23 months under heavy abrasion | Polyurethaneclad modular panels last 812 months | +300% service life |
| Screening Efficiency | ~85% efficiency for midsize separation due to blinding | Maintains >92% efficiency via antiblinding systems | +78% sustained efficiency |
| Maintenance Downtime | 812 hours monthly for cleaning bearing checks panel replacement
| Energy Consumption per Ton ~0.12 kWh/ton processed
| Breeze (10mm) Contamination in Product Fraction
5. TECHNICAL SPECIFICATIONS
Capacity / Rating: Modeldependent from 200 TPH to over 1500 TPH throughput capacity standard designs available
Power Requirements: Drive motor range from 7.5 kW to 45 kW depending on screen size mass excitation force
Material Specifications: Highstress frame components S355JR steel side plates wear liners Hardox®400 Abrasionresistant polyurethane rubber composite deck materials
Physical Dimensions (Typical Model): Deck Size (LxW): 3m x1 .5m Overall length:~4 .2m Overall width:~2 .8m Height:~1 .6m Weight:~6500kg
Environmental Operating Range: Ambient temperature:20°C +50°C Feed material temperature upto120°C(max) Weather protection IP65 enclosure optional
6. APPLICATION SCENARIOS
Metallurgical Coke Plant Blast Furnace Feed Preparation Challenge:: Existing screens blinded within hours due high moisture content in quenched coke causing severe bottleneck before furnace feed bins resulting in inconsistent size distribution affecting furnace efficiency
Solution:: Installation two large doubledeck Coke Vibration Screens equipped ball tray antiblinding decks isolated base frames
Results:: Screening availability increased from94%. Blast furnace feed consistency improved quantified as+/5mm size variation reducedby30%. Annual maintenance labor hours decreasedby1200
Coke Sorting Terminal Product Diversification Challenge:: Terminal needed produce three distinct saleable products(>50mm2550mm<25mm)from single feed stream but existing separator generated excessive fines(<10mm)in midrange fraction reducing its market value
Solution:: Implementation multislope Coke Vibration Screen with precision elliptical vibration finetuning deck tensioning system
Results:: Product purity each fraction achieved>95%. Revenue from midrange(2550mm)fraction increasedby18%due reduced fines content System handled variable feed rates without performance degradation
7. COMMERCIAL CONSIDERATIONS
Equipment Pricing Tiers: Entrylevel standard duty screens(starting~$25000);Heavyduty customengineered units($65000$200000+)based size configuration options
Optional Features / Upgrades: Stainless steel construction critical areas hotmaterial handling kits spray bar systems different deck types(harps tensioned polyurethane etc.) variable frequency drives advanced condition monitoring sensors
Service Packages: Tiered annual maintenance contracts covering inspection parts discounts priority support Extended warranty available upto36months Comprehensive training programs operational maintenance staff included
Financing Options Available through partners include equipment leasing longterm rental purchase plans tailored capital expenditure cycles Project financing considered largescale installations
8. FAQ
Q1 How do we determine correct screen size deck configuration our specific capacity requirements?
Our engineering team requires your detailed feed rate particle size distribution(P80 D50)desired product splits moisture content This data allows us model recommend optimal machine specifications guarantee performance
Q2 Can this equipment integrate our existing PLC control system material handling network?
Yes standard designs include control panel compatible common industrial protocols(Profibus Ethernet/IP etc.) We provide necessary interface documentation facilitate integration your plant SCADA system
Q3 What typical installation timeline foundation requirements?
With isolated design foundation requirements less stringent than older screens Typical installation including positioning electrical mechanical connection commissioning takes510working days depending complexity Preinstallation foundation drawings issued advance
Q4 Are spare parts readily available what expected lead times?
We maintain strategic inventory critical wear parts(decks bearings exciters)at regional hubs Standard parts ship within48hours Custom components have lead times communicated upfront during purchase Longterm supply agreements ensure ongoing support
Q5 How does equipment handle variations feed rate material composition?
Robust design accommodates reasonable fluctuations Variable speed drive option allows operators adjust vibration intensity optimize performance realtime changing conditions ensuring consistent output quality