1. PAINPOINT DRIVEN OPENING

Is your coke handling operation struggling with persistent bottlenecks, excessive fines generation, and unplanned maintenance costs? Inefficient screening directly impacts your plant’s bottom line through lost product, increased energy consumption for downstream processes, and costly downtime for screen deck replacements. Are you currently facing these challenges?
Blinding & Carryover: Moisture and sticky fines blind screen meshes, reducing effective screening area and forcing material to carry over unscreened, contaminating your product fractions.
Excessive Wear & Maintenance: The abrasive nature of hot coke rapidly degrades standard screen panels and deck components, leading to frequent shutdowns for replacements and high spare parts inventories.
Inefficient Separation: Inconsistent vibration or inadequate screening area results in poor size distribution control, sending offspec material to crushers or battery bunkers, disrupting the entire production chain.
Structural Fatigue: The intense impact loads from coke discharge can cause premature failure of the screen body and support structures, risking major operational failure.

The right coke vibration screen is not just a separator; it’s a critical asset for throughput stability and product quality control.

2. PRODUCT OVERVIEW

The heavyduty coke vibration screen is a highcapacity, linear motion screening machine engineered for the primary sizing and scalping of metallurgical coke. It is designed to withstand extreme abrasion, impact, and thermal stress in coke handling plants.

Operational Workflow:
1. Feed & Distribution: Hot or cooled coke from a conveyor is discharged onto a robust feed box or plate, distributing the material evenly across the full width of the first screen deck.
2. Primary Stratification & Sizing: The powerful dualvibrator motor drive generates a linear throwing motion. This action stratifies the material bed, forcing fines downward through the apertures of the upper deck(s) while conveying oversize toward the discharge end.
3. Fraction Separation: Multiple deck levels (typically 2 or 3) with precisely sized screen media (rails, woven wire, or polyurethane panels) separate the coke into defined product streams (e.g., blast furnace coke, nut coke, breeze).
4. Discharge: Sized fractions are discharged via separate chutes for transport to storage bunkers or downstream processes.

Application Scope & Limitations:
Scope: Ideal for primary screening of metallurgical coke after quenching or crushing; scalping of ovenrun coke; separation of coke breeze from larger fractions in byproduct recovery.
Limitations: Not designed as a dewatering screen for slurries. Maximum feed temperature is determined by specific component selection (e.g., heatresistant seals, motor isolators). Extremely sticky materials may require pretreatment or specialized deck cleaning systems.

3. CORE FEATURES

HeavyDuty Deck Support System | Technical Basis: Reinforced crossmembers with abrasionresistant wear liners | Operational Benefit: Protects the main frame from direct material impact, drastically extending structural life | ROI Impact: Eliminates costly frame repairs; reduces lifetime structural maintenance costs by an estimated 6070%.

Dual CounterRotating Vibrator Drive | Technical Basis: Two synchronized motors generating a pure linear force | Operational Benefit: Provides consistent material travel speed and stratification without elliptical motion; minimal transmission wear | ROI Impact: Ensures stable product sizing yearround; reduces drive maintenance compared to eccentric shaft designs.

QuickChange Screen Media System | Technical Basis: Modular panel clamping with frontaccess tensioning | Operational Benefit: Allows single operators to replace worn panels in under an hour without specialized tools | ROI Impact: Cuts downtime for media changes by up to 75%, directly increasing plant availability.

Advanced Isolation Mounting | Technical Basis: Multilayered rubbercork or steel spring isolators tuned to machine frequency | Operational Benefit: Absorbs over 95% of dynamic forces before they reach the support structure | ROI Impact: Protects building infrastructure from vibration damage; eliminates secondary support costs.

Hot Material Construction Package | Technical Basis: Heatdeflecting covers on vibrators, hightemp labyrinth seals on bearings, heatresistant paint systems | Operational Benefit: Ensures reliable operation when handling hot coke directly from quench towers | ROI Impact: Increases component lifespan in highheat applications by over 40%, protecting your capital investment.

Centralized Lubrication System (Optional) | Technical Basis: Automated greasing lines feeding all critical bearing points on vibrator shafts | Operational Benefit: Guarantees proper lubrication intervals in hardtoaccess areas under all operating conditions | ROI Impact: Prevents catastrophic bearing failure; extends bearing service life by up to 50%.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Our Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Panel Life (Upper Deck) | Standard Hardox 400 Rails ~4 Months| Proprietary Alloy Cast Rails with Hardfacing ~9 Months| +125% service life |
| Screening Efficiency (for target fraction)| ~8892% efficiency under load| Consistent >95% efficiency under load| +35 percentage points |
| Annual Downtime for Screen Maintenance| ~120150 hours/year| 50% reduction |
| Dynamic Force Transmitted to Structure| High transmission requiring reinforced foundations|95% reduction in transmitted force |
| Power Consumption per Ton Screened| Baseline = 100%| Optimized mass/force balance reduces consumption by ~15%| 15% lower energy cost |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: From 500 TPH to over 2,500 TPH throughput capacity.
Screen Decks: Typically 2 or 3 decks; custom configurations available.
Drive Power: Dual vibrator motors ranging from 2 x 15 kW to 2 x 55 kW depending on model size and duty.
Vibration Frequency/Frequency: Fixed frequency typically between 9001000 RPM; stroke adjustable via counterweight configuration.
Construction Materials: Main frame heavyduty steel plate (S355JR+). Wear surfaces AR400 steel liners. Screen media options include alloy cast rails (standard), tensioned woven wire mesh, or modular polyurethane panels.
Physical Dimensions (Example Model): Widths from 1.8m to 3.6m; lengths from 6m to over 11m overall.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Specific hotduty packages allow handling feed material up to ~200°C intermittently.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feed Preparation

Challenge: A major steel producer experienced rapid blinding of woven wire screens during humid conditions at their BF coke bunker station. This caused significant nut coke fraction carryover into blast furnace feed bins (~12%), disrupting burden permeability and increasing fuel rate.
Solution: Implementation of two largecapacity linear motion screens fitted with nonblinding rod deck media on the upper decks for scalping oversize and openprofile polyurethane panels on lower decks for precise nut/breeze separation.
Results: Screening efficiency stabilized above 96%. Carryover was reduced to <3%. The plant reported an annual reduction in fuel rate attributed partly to improved burden control alongside a 65% drop in monthly screenrelated downtime.

Coke Plant – ByProduct Recovery Circuit

Challenge: A standalone coking plant needed to maximize recovery of saleable “nut” coke from its crushing circuit but struggled with excessive generation of undersize “breeze” due to aggressive screening action degrading fragile pieces.
Solution:: Installation of a threedeck unit featuring adjustable stroke length via external counterweights on its vibrator motors was selected. This allowed operators finetune intensity based on feed characteristics..
Results: By optimizing stroke,,the plant increased yield within target nut size range (+8%) while reducing undersize generation (15%). The gentler handling also extended lowerdeck panel life by approximately 30%.

7 COMMERCIAL CONSIDERATIONS

Pricing Tiers
• Standard Duty Units: For cooledcoke applications with moderate tonnage (<1000 TPH). Offers core reliability features at an entry point..
• HeavyDuty / Hot Material Units: Includes full abrasion/heat packages,,upgraded drives,,and isolation systems.. Priced approximately 2540% above standard duty..
• Custom HighCapacity Units: Engineered solutions exceeding 2000 TPH capacity often require projectspecific pricing based detailed engineering study..

Optional Features
• Enclosed Dust Housing: With flanged connections..
• Various Chute Configurations: Including wearlined,,insulated,,or heated designs..
• Vibration Monitoring System: With sensors providing realtime data predictive maintenance schedules..
• Variable Frequency Drive Control: For precise adjustment material travel speed..

Service Packages
• Commissioning Supervision
• Annual Inspection Contracts
• Critical Spares Kits
• Onsite Training Operators Maintenance Staff

Financing Options
Capital equipment financing,,operating leases available through partners terms ranging 24 84 months subject credit approval..

8 FAQ

Q1 How do I determine correct size model my application?
A Selection requires analysis total feed tonnage particle size distribution desired products moisture content We provide detailed questionnaire our engineers use recommend specific model configuration

Q2 Can existing foundation be used replacement unit?
A Possibly Our team requires drawings existing structure load data new unit We design adapter frames facilitate retrofits minimizing civil work costs

Q3 What typical lead time delivery?
A For standard models within catalog lead time ranges 16 weeks exworks Custom highcapacity units require longer engineering manufacturing schedule

Q4 Are spare parts readily available?
A Yes We maintain global inventory critical wearing parts including vibrator assemblies deck panels isolation elements Standard parts shipped within hours emergency orders

Q5 Do you offer performance guarantees?
A Yes We guarantee mechanical performance throughput capacity screening efficiency based agreedupon test protocols provided feed specifications met

Q6 How handle installation commissioning?
A We provide comprehensive installation manuals foundation drawings supervision available optional extra ensure correct setup initial operation

Q7 What expected operational lifespan main structure?
A With proper maintenance isolation our screens designed minimum years service before major structural overhaul required Field data supports this timeline numerous installations