Subject: Optimizing Your Coke Screening Operations: A Technical Analysis of Vibration Screen Performance and Cost Efficiency

1. PAINPOINT DRIVEN OPENING

In coke processing, three operational challenges consistently erode profitability: blinding of screen media due to moisture and fines, mechanical failure from impact loading of large lumps, and inconsistent particle size distribution leading to downstream rejection. Industry data indicates that unscheduled downtime from screen deck failures costs plants between $2,500 and $8,000 per hour in lost production. Additionally, a 2% increase in fines carryover can reduce blast furnace efficiency by 0.5%, directly impacting your energy costs.

Are your current screens handling the abrasive nature of metallurgical coke without requiring weekly media replacement? Can your equipment maintain a consistent cut point at 25mm or 50mm when feed moisture fluctuates between 5% and 12%? If your answer involves frequent welding repairs or manual cleaning, you are losing margin on every ton processed.

2. PRODUCT OVERVIEW

The Coke Vibration Screen is a heavyduty, linearmotion vibratory classifier engineered specifically for the dry screening of metallurgical and petroleum coke. It operates on a dualshaft, selfsynchronizing exciter system that generates a highGforce, straightline stroke to stratify and separate material.

Operational Workflow:
1. Feed Inlet: Material enters via a chute, distributed across the full width of the screen deck to prevent material pileup.
2. Stratification: Highfrequency vibration (8501050 RPM) causes fine particles to migrate to the bottom of the bed.
3. Separation: Material passes over multiple decks (typically 23) with specific aperture sizes (e.g., 6mm, 25mm, 50mm).
4. Oversize Discharge: +50mm material is ejected from the top deck for crushing or recirculation.
5. Undersize Collection: Fines (6mm) pass through the bottom deck to a separate conveyor.

Application Scope: Ideal for dry screening of coke breeze, nut coke, and lump coke. Limitations: Not recommended for wet screening applications above 15% moisture without heated deck options, as blinding will occur.

3. CORE FEATURES

HighStrength Side Plate Construction | Technical Basis: Fabricated from 8mm to 12mm Q345B steel with internal stiffening ribs | Operational Benefit: Resists flexing and cracking under the impact of 200mm+ coke lumps | ROI Impact: Reduces structural repair costs by 40% over standard 6mm plate designs

SelfCleaning Tensioned Screen Media | Technical Basis: Modular polyurethane or springsteel wire panels with 5degree crown angle | Operational Benefit: Prevents material pegging in apertures, maintaining 95% open area | ROI Impact: Eliminates 23 hours of daily manual cleaning labor

DualShaft Exciter with Oil Lubrication | Technical Basis: Two counterrotating shafts with splashlubricated spherical roller bearings | Operational Benefit: Generates a consistent 57mm stroke without belt slippage | ROI Impact: Extends bearing life to 8,000+ operating hours, reducing replacement costs by 60%

Adjustable Amplitude Mechanism | Technical Basis: Movable counterweight plates on exciter shafts | Operational Benefit: Allows finetuning of Gforce (46 G) for varying coke densities | ROI Impact: Optimizes throughput by 15% when switching between petroleum and metallurgical coke

DustTight Sealing System | Technical Basis: Rubber compression seals between decks and discharge chutes | Operational Benefit: Contains fine coke dust within the machine, reducing fugitive emissions | ROI Impact: Avoids EPA fines and reduces plant housekeeping costs

QuickRelease Deck Clamps | Technical Basis: Pneumatic or manual wedgelock systems | Operational Benefit: Enables screen media changeout in under 30 minutes per deck | ROI Impact: Reduces changeover downtime by 70% compared to bolted systems

HeavyDuty Coil Spring Isolation | Technical Basis: Steel coil springs with 30mm static deflection | Operational Benefit: Transmits less than 5% vibration to support structure | ROI Impact: Eliminates need for reinforced concrete foundations, saving $15,000$25,000 in civil works

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Generic Screen) | Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency at 25mm | 8588% | 9396% | +8% |
| Deck Life (Abrasive Coke) | 400600 hours | 1,2001,800 hours | +200% |
| Mean Time Between Failures (MTBF) | 1,500 hours | 4,000 hours | +166% |
| Power Consumption per Ton | 0.8 kWh/ton | 0.55 kWh/ton | 31% |
| Noise Level at 1 Meter | 95 dB(A) | 85 dB(A) | 10 dB(A) |
| Media Change Time (per deck) | 90 minutes | 25 minutes | 72% |

5. TECHNICAL SPECIFICATIONS

| Parameter | Specification |
| : | : |
| Model Range | CKS1536 to CKS2460 |
| Capacity Rating | 50 – 350 tons per hour (depending on deck area and cut point) |
| Screening Area | 5.4 m² to 14.4 m² per deck |
| Motor Power | 2 x 5.5 kW to 2 x 15 kW (dual drive) |
| Vibration Frequency | 850 – 1050 RPM (adjustable via VFD) |
| Stroke (Amplitude) | 5 – 8 mm (adjustable) |
| Material of Construction | Q345B steel (body), Hardox 450 (impact zones), 60Si2Mn (springs) |
| Screen Media Options | Polyurethane (815mm), Spring Steel (350mm), Perforated Plate (50100mm) |
| Operating Temperature Range | 20°C to +80°C (ambient); product temp up to 150°C |
| Physical Dimensions (CKS1848) | 4,800mm L x 2,400mm W x 2,100mm H |
| Total Weight | 4,500 kg to 12,000 kg |

6. APPLICATION SCENARIOS

Metallurgical Coke Plant – Primary Sizing

Challenge: A steel mill was experiencing 12% fines carryover into their blast furnace feed, causing increased slag volume and coke rate.
Solution: Installed a CKS2460 Coke Vibration Screen with 25mm polyurethane panels on the top deck and 6mm wire mesh on the bottom.
Results: Fines carryover reduced to 4.5%. Blast furnace coke rate decreased by 8 kg per ton of hot metal, saving $1.2M annually in coke purchases.

Petroleum Coke Calcining Facility – Product Recovery

Challenge: A calciner was losing 5% of product value due to degradation during screening with conventional circular motion screens.
Solution: Replaced with a linearmotion Coke Vibration Screen operating at 5mm stroke and 900 RPM.
Results: Product degradation reduced by 60%. The plant recovered an additional 3,000 tons of saleable 6mm coke per year, valued at $180,000.

Coke Breeze Handling – Power Plant Fuel

Challenge: A power plant was rejecting 20% of their coke breeze due to +3mm oversize in the pulverizer feed.
Solution: Deployed a CKS1536 screen with 3mm slotted wire mesh and heated deck option for moisture control.
Results: Pulverizer throughput increased by 18%. Rejected material dropped to 3%, allowing the plant to burn lowercost coke breeze instead of coal.

7. COMMERCIAL CONSIDERATIONS

Equipment Pricing Tiers (FOB Port, USD):

• Standard Configuration (CKS1536): $28,000 – $38,000 (2deck, carbon steel, standard wire mesh)
• HeavyDuty Configuration (CKS1848): $45,000 – $62,000 (3deck, Hardox liners, polyurethane media)
• Premium Configuration (CKS2460): $78,000 – $105,000 (VFD drive, heated decks, dust collection ports)

Optional Features:

• Heated Deck System: $4,500 – $8,000 (prevents blinding in highmoisture coke)
• CeramicLined Feed Box: $3,200 (extends wear life in impact zones by 300%)
• Remote Monitoring Package: $2,800 (vibration sensors and bearing temperature monitoring)

Service Packages:

• Basic (1 Year): Includes spare spring set and seal kit ($1,500)
• Comprehensive (3 Year): Includes annual inspection, one media change, and priority technical support ($8,500)

Financing Options:

• Net 30 terms for qualified buyers
• 12month leasetoown with 10% residual value
• Volume discounts: 5% off for orders of 3+ units

8. FAQ

Q: Can this Coke Vibration Screen handle feed with 10% moisture content?
A: Yes, up to 12% moisture with standard polyurethane media. For moisture above 12%, we recommend the heated deck option to prevent screen blinding.

Q: What is the typical lead time for a CKS1848 model?
A: Standard lead time is 68 weeks from order confirmation. Rush orders can be expedited to 4 weeks with a 10% surcharge.

Q: How does this screen compare to a banana screen for coke applications?
A: Banana screens offer higher capacity per area but have higher capital cost and more complex media replacement. Our linearmotion screen provides better efficiency for precise cut points (e.g., 25mm) and lower maintenance costs.

Q: What warranty is provided on the exciter assembly?
A: The exciter assembly carries a 24month warranty against manufacturing defects, provided oil changes are performed every 500 hours.

Q: Can I retrofit this screen into my existing support structure?
A: Yes, but we recommend a structural analysis. Our dynamic load is typically 30% lower than older designs due to efficient spring isolation. We provide certified foundation drawings.

Q: What screen media is best for 6mm coke breeze?
A: For coke breeze, we recommend 3mm slotted wire mesh or polyurethane panels with 4mm square apertures. Wire mesh offers higher open area, while polyurethane provides 3x longer wear life.

Q: Do you provide onsite commissioning support?
A: Yes. Our service engineer can be onsite for 35 days for installation supervision, alignment, and operator training. This is included in the Premium Configuration pricing.