1. PAINPOINT DRIVEN OPENING

Is your coke handling and classification process a source of chronic downtime and cost overruns? For plant managers overseeing coke screening, common operational challenges include:
Blinding & Carryover: Fine, sticky coke particles blind screen decks, while oversized material carries over into finished product bins, compromising quality and forcing manual intervention.
Excessive Maintenance Cycles: The abrasive nature of coke accelerates wear on screen panels, bearings, and exciters, leading to frequent, unplanned shutdowns for parts replacement.
Inefficient Fines Separation: Inconsistent vibration patterns fail to properly separate breeze from nut coke, resulting in product specification misses and lost revenue from misclassified material.
Structural Fatigue & Failure: Highcycle operations under heavy load lead to weld cracks and structural failures in the screen body, creating major capital repair events.

These issues translate directly into quantifiable losses: hours of lost production per month, rising spare parts inventories, and inconsistent product quality affecting customer contracts. How do you achieve reliable separation with minimal maintenance? The answer lies in specifying a purposeengineered Coke Vibration Screen.

2. PRODUCT OVERVIEW

A Coke Vibration Screen is a heavyduty industrial screening machine designed for the scalping, sizing, and dedusting of metallurgical coke and petroleum coke. Its core function is to separate bulk coke into precise fractions (e.g., blast furnace nut coke, foundry coke, breeze) using controlled vibratory motion.

Operational Workflow:
1. Feed & Distribution: Bulk coke is fed onto the screen’s robust feed box, which evenly distributes material across the full width of the first screening deck.
2. Stratification & Separation: Highintensity vibration stratifies the material; fines pass through upper deck apertures while larger particles travel across the deck surface.
3. Sizing & Discharge: Multideck configurations allow for sequential sizing. Correctly sized fractions discharge from designated discharge spouts into separate conveyors or bins for downstream processing.

Application Scope: Primary sizing of ovendischarged coke, scalpandscreen circuits in byproduct plants, final product grading before shipment, and dedusting applications.

Limitations: Not designed for wet screening or slurry applications. Maximum lump size is constrained by feed chute and deck aperture design; typically handles feed sizes up to 300mm.

3. CORE FEATURES

HeavyDuty Deck Support System | Technical Basis: Reinforced crossmembers with bolted clamp rails | Operational Benefit: Eliminates welded deck frame fatigue; allows for rapid panel changeout (under 4 hours vs. 12+). | ROI Impact: Reduces downtime for maintenance by over 65% and extends structural life beyond 10 years.

AntiBlinding Ball Deck System | Technical Basis: Rubber balls trapped beneath screen panels provide continuous percussive cleaning | Operational Benefit: Prevents aperture clogging from sticky fines, maintaining consistent throughput and screening efficiency above 95%. | ROI Impact: Ensures onspec product yield, reducing qualityrelated rejections by an estimated 18%.

Dual CounterRotating Exciter Drive | Technical Basis: Two synchronized eccentric shafts generating a linear vibratory motion | Operational Benefit: Delivers powerful yet controllable material travel speed with minimal transmitted stress to the support structure. | ROI Impact: Lowers structural maintenance costs and improves bearing life (typically L10 > 30,000 hours).

Modular Polyurethane Screen Panels | Technical Basis: Highresilience PU with varied aperture design (square, slotted) | Operational Benefit: Abrasion resistance is 810x that of steel wire cloth; significantly reduces noise levels (<85 dB(A)). | ROI Impact: Cuts panel replacement frequency and inventory costs while improving workplace safety compliance.

Enclosed DustTight Body Design | Technical Basis: Continuous gasketing between side plates and decks with multiple dust extraction ports | Operational Benefit: Contains particulate matter at transfer points, supporting plantwide emission control targets. | ROI Impact: Mitigates environmental compliance risks and reduces cleanup labor.

PLCIntegrated Condition Monitoring | Technical Basis: Vibration sensors and temperature probes on exciter bearings linked to plant DCS | Operational Benefit: Provides realtime health data for predictive maintenance scheduling. | ROI Impact: Prevents catastrophic bearing failures; enables planned shutdowns versus emergency stops.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Conventional Screens) | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (for 25mm fines) | 8892% sustained efficiency before blinding affects output. Field data shows our solution maintains >95% efficiency over longer campaigns due to antiblinding systems.| >95% sustained efficiency maintained over full panel life cycle.| +7% average improvement in yield accuracy |
| Annual Deck Panel Replacement Cost (for primary sizing) Based on abrasive wear rates in hightonnage applications.| Annual replacement required with standard steel panels.| Polyurethane panel lifespan averages 3x longer than highcarbon steel wire cloth.| ~67% reduction in annual panel cost |
| Mean Time Between Failure (MTBF) Major Components Structural integrity under full load conditions.| ~812 months before weld inspection/repair on deck supports is needed.| Design eliminates critical weld points in stress zones; MTBF exceeds 24 months.| +100% improvement in structural reliability |
| Total Maintenance Hours Per Year Includes routine bearing checks,lubrication,and panel changes based on industry surveys.| Estimated 80120 hours/year for a single unit.| Predictive monitoring & quickchange decks reduce total to ~40 hours/year.| ~60% reduction in direct labor hours |

5. TECHNICAL SPECIFICATIONS

Capacity / Rating: Modeldependent; standard range from 500 MTPH to 2,500 MTPH of bulk coke.
Power Requirements: Dual exciter drives from 2 x 15 kW to 2 x 55 kW motors (400/690V AC), depending on model size.
Material Specifications:
Side Plates & Deck Frames: Hightensile carbon steel (Q345B or equivalent).
Screen Decks / Panels: Modular polyurethane or rubberclad steel panels.
Liners / Wear Protection: AR400 abrasionresistant steel at all feed points.
Physical Dimensions (Typical Large Unit): Overall length ~7m; width ~3m; height ~2m; weight approx. 1218 tonnes.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Dust protection rating standard at IP65 for electrical components.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feed Circuit

Challenge A major steel producer faced persistent blinding on their primary coke screens during humid months.This caused nut coke contamination with excessive fines (6mm), risking blast furnace permeability,and required biweekly manual cleaning halting the line.Their existing screens' welded decks were prone to cracking,causing further unplanned downtime.Solution Implementation of two new heavyduty Coke Vibration Screens featuring sealed balltray antiblinding systems,a bolted modular deck structure,and polyurethane panels.The installation was timed with a scheduled furnace reline.The Results Screening efficiency for 6mm material stabilized at ≥96%.Manual cleaning was eliminated.Product consistency improved,directly contributing to stable furnace operation.Maintenance downtime related to screening was reduced by an estimated75%,and no structural repairs have been required in three years of operation.

Petroleum Coke Processing Terminal

Challenge At a bulk export terminal handling calcined petroleum coke,vibrationinduced fatigue was causing catastrophic failures in screen support structures every1418 months.Dust emission at transfer points also exceeded new local regulations,due to poor sealing on old equipment.Solution Procurement of customengineered Coke Vibration Screens with reinforced,twinbeam base frames designed for higher Gforces,and fully enclosed,dusttight bodies integrated with the plant's extraction system.The Results Structural integrity has been maintained beyond36 months with no signs of stress fatigue.Dust emissions at the screening station measured below permitted levels,satisfying compliance audits.The terminal reported a22% reduction in total costofownership per ton screened over two years due to lower repair costs

7.COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are primarily determined by size(capacity),material specifications,and optional features.Base models are offered as complete units ready for installation onto existing support structures.Pricing follows an industrial capital goods model rather than light commercial equipment pricing.Optional features that affect cost include:
Advanced condition monitoring packages(vs.basic local gauges)
Specialized wear liners(ceramic composite vsstandard AR steel)
Explosionproof motor specifications(for certain environments)
Custom discharge spout configurations

Service packages are available separately,ranging from basic commissioning supervision up through comprehensive multiyear performance contracts that include scheduled inspections,predictive monitoring analysis,and guaranteed spare parts availability.Financing options through partner institutions can structure payments as operating leases or term loans aligned with project finance timelines,making capital appropriation easier

8.FAQ

Q1.Are your Coke Vibration Screens compatible with our existing feedand discharge conveyor heights?
A1.Dimensional drawings are provided during the quotation phase.Customizable leg heights,support pedestal designs,and feed box configurations ensure interface compatibility with your current layout

Q2.What is the expected impact on our overall plant vibration levels?
A2.When properly installed on supplied isolation springs or rubber buffers,the transmitted dynamic force to the building structure is minimal.Field measurements typically show no measurable increase in adjacent structural vibration

Q3.How does this equipment handle variationsin feed rate or lump size?
A3.The linear motion drive provides consistent conveying velocity even under variable load conditions.For significant feedstock changes,a simple adjustmentof exciter weights can modify stroke amplitude.Optional variable frequency drives(VFDs)allow operators totune performance without mechanical changes

Q4.What are typical lead timesfor procurementand delivery?
A4.For standard models within our catalog,fabrication lead time ranges from14to20weeks exworks.Custom engineered solutions may require22to28weeks.Detailed schedules are confirmed upon order placement

Q5.What commercial termsare standard?
A5.Terms are typically FOB manufacturing facilityor CIFto major port.Payment commonly followsa30/70structure(30%with order70%against shipping documents).Extended terms may be available subjectto credit approval

Q6.Is onsite technical support provided during installationand commissioning?
A6.Commissioning supervisionby a factory engineeris includedwith all purchases.This ensures proper mechanical setup electrical connection vibration tuningand operator training Documentation including detailed maintenance manualsand parts listsis provided digitallyandin hardcopy format