1. PAINPOINT DRIVEN OPENING

Is your coke processing operation struggling with inefficient screening that impacts final product quality and plant throughput? Common challenges with conventional vibration screens in this harsh application include:

Premature Screen Cloth Failure: Abrasive coke breeze and thermal cycling cause rapid wear, leading to frequent, costly shutdowns for media replacement and unplanned downtime.
Inefficient Fines Separation: Inconsistent vibration or screen blinding results in undersize material contaminating the product stream or valuable fines being lost to waste, directly affecting yield and revenue.
Excessive Structural Fatigue: The combined load of abrasive coke and constant vibratory forces can lead to weld cracks, side plate failures, and catastrophic structural damage, requiring major rebuilds.
High Maintenance Burden: Bearings, motors, and springs under constant stress from heavy loads demand excessive lubrication, inspection, and replacement, driving up operational costs.

Are you seeking a screening solution that delivers consistent grade control, maximizes uptime in a 24/7 environment, and reduces your total cost of ownership?

2. PRODUCT OVERVIEW

Our engineered Coke Vibration Screen Processing Plant is a heavyduty linear motion screening system designed for the precise sizing and scalping of metallurgical coke and coke breeze in processing circuits. It is built to handle hightonnage, abrasive materials while operating reliably in demanding plant conditions.

Operational Workflow:
1. Feed & Distribution: Sized coke from crushers or ovens is evenly distributed across the full width of the screen’s robust feed box.
2. Precise Stratification & Separation: Dual vibratory motors generate a linear motion that stratifies material, forcing fines through the specified aperture of the durable screen cloth while conveying oversize material to discharge.
3. Efficient Discharge: Separated fractions—oversize product (e.g., +25mm blast furnace coke) and undersize fines (coke breeze)—are discharged into distinct chutes for downstream processing or stockpiling.

Application Scope: Primary sizing of metallurgical coke, scalping of oven charge materials, dedusting of coke breeze, and final product separation in coke handling plants.

Limitations: This equipment is engineered for dry screening applications. Performance in wet screening circuits or with highly sticky materials may require specific configuration adjustments.

3. CORE FEATURES

HeavyDuty Deck Assembly | Technical Basis: Modular, boltin tensioning system with reinforced crossmembers | Operational Benefit: Enables rapid, individual panel changes without full deck disassembly, minimizing downtime for cloth replacement. | ROI Impact: Reduces screen media changeout time by up to 40%, increasing plant availability.

Controlled Vibration Mechanism | Technical Basis: Synchronized dual outofbalance motors generating a linear throw; force can be adjusted via external counterweights. | Operational Benefit: Operators can finetune amplitude for optimal material travel rate and separation efficiency for varying feed conditions. | ROI Impact: Improves screening efficiency by 515%, reducing recirculating load and improving product grade consistency.

AbrasionResistant Lining System | Technical Basis: Bolton wear plates made from AR400 steel at all critical impact points (feed box, discharge lips). | Operational Benefit: Protects the main frame structure from wear, extending the equipment’s structural service life by several years. | ROI Impact: Eliminates need for frequent weld repair on the frame body, cutting longterm maintenance capital expenditure.

DustEncapsulated Vibrator Motors | Technical Basis: IP66rated protection with labyrinth seals on drive shafts. | Operational Benefit: Prevents ingress of abrasive coke dust into motor bearings, the leading cause of vibrator unit failure. | ROI Impact: Extends bearing service life by over 50%, reducing spare parts costs and failurerelated stoppages.

HuckBolted Frame Construction | Technical Basis: Highshear strength fasteners used throughout the main side plate and crossmember joints. | Operational Benefit: Creates a rigid frame resistant to fatigue cracking under dynamic loads compared to traditional welded designs. | ROI Impact: Dramatically reduces risk of unexpected structural failure, ensuring multiyear operational integrity with minimal inspection overhead.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Screen Cloth Life (Primary Deck) | 68 weeks under standard abrasion | 1014 weeks with recommended media | +4075% longer service life |
| Annual Bearing MTBF (Vibrator Units) | ~8,000 hours | 12,000+ hours demonstrated in field data| +50% improvement |
| Structural Integrity Period (to first major weld repair) | 1824 months| 36+ months documented in similar installations| +100% improvement |
| Screening Efficiency (for 5mm separation)| ~85% consistent efficiency| 9295% achievable with optimized throw/angle| +812% increase in yield accuracy|
Mean Time Between Failures

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Sizes from 1.2m x 3m to 2.4m x 6m; throughput capacity from 150 to over 1000 metric tons per hour depending on aperture size and feed gradation.
Drive Unit: Dual externallymounted vibratory motors; total power range from 15 kW to 45 kW per motor pair.
Deck Construction: Multislope capable; up to three decks standard. Features reinforced crossmembers with rubber buffer coating to protect screen cloth.
Frame & Body Material: Main side plates constructed from highyield strength steel (Q345B minimum). Critical wear areas lined with replaceable AR400 steel liners.
Physical Dimensions & Weight: Varies significantly by model; largest model (~2.4m x 6m) approx. weight of 1214 tonnes excluding support structure.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust protection standard; optional weather covers available for outdoor installation.

6. APPLICATION SCENARIOS

Integrated Steel Plant Coke Handling Facility

Challenge: A major steel producer faced excessive downtime every 67 weeks for screen cloth changes on their primary coke screens due to abrasion wear from blast furnacegrade coke (+25mm). Unplanned stoppages were disrupting steady feedstock supply to the furnaces.
Solution: Implementation of our heavyduty Coke Vibration Screen featuring a quickchange deck system and ARlined feed zone.
Results: Screen media changeout intervals extended to an average of 11 weeks per setup time reduced by onethird due to modular design). This contributed to an estimated increase in annual plant availability by over 120 hours.

Merchant Coke Producer – Breeze Recovery Circuit

Challenge: Significant volumes of valuable sub10mm coke fines (“breeze”) were being lost as waste due to inefficient separation on aging screens suffering from frequent blinding.
Solution: Installation of a twodeck linear motion screen configured specifically for dedusting at high capacity using nonblinding polyurethane screen panels on the lower deck.
Results: Screening efficiency for 5mm material improved from an estimated ~82% to consistently measured levels above >93%. This allowed recovery of an additional ~18 tonnes per day of saleable breeze product directly impacting revenue.

7 COMMERCIAL CONSIDERATIONS

Our Coke Vibration Screens are offered as engineeredtoorder solutions based on your specific capacity requirements:

Standard Tier (ST): Includes core heavyduty frame design base vibrator units dust encapsulation basic liners Designed as reliable replacements for existing units
Performance Tier (PT):(Most common choice) Includes all ST features plus enhanced quickchange deck system adjustable counterweight vibrators upgraded AR400 liners at all wear points rubber buffer coated crossmembers
Premium Tier (PMT):(For maximum uptime operations) Includes all PT features plus condition monitoring sensor ports premium SKF/FAG class bearings optional automated lubrication system preinstalled

Optional features include custom chutework weather covers explosionproof motor ratings different types

Service packages range from basic commissioning supervision comprehensive multiyear maintenance agreements including scheduled inspections parts kits priority support

Financing options including equipment leasing are available through our partners allowing you preserve capital expenditure budgets

FAQ

What tonnage range can your Coke Vibration Screens handle?
Our models are scalable designed handle capacities ranging between metric tons hour depending size number decks required aperture We will specify correct model based detailed analysis feed material specifications

How does this screen handle thermal expansion hot feed material?
Design incorporates allowances thermal expansion key areas such between deck frames main side plates Use hightemperature grease bearings standard Allowing handle typical temperatures associated cooled metallurgical without compromising integrity

What type screen media do you recommend?
We provide technical support select optimal media based application For primary sizing coarse coke recommend rugged punched plate secondary sizing fine separation recommend tensioned polyurethane or woven wire panels offer best balance life resistance blinding

Can integrate existing plant PLC control systems?
Yes The vibratory motor starters can be interfaced plant control systems provide standard running fault feedback signals Optional variable frequency drives be supplied allow remote adjustment vibration intensity match realtime conditions

What typical delivery lead time engineered unit?
For standard configurations lead time typically weeks receipt order Customized designs may require additional engineering time We maintain critical spare parts inventory ensure support after installation