1. PAINPOINT DRIVEN OPENING

Is your coke handling operation plagued by persistent bottlenecks and escalating costs? For plant managers overseeing commercial coke production, screening efficiency directly impacts profitability and uptime. Common challenges include:

Blinding & Carryover: Fine, sticky coke particles blind screen decks, while oversized material carries over into finished product silos. This results in offspec product, customer rejections, and costly reprocessing.
Excessive Downtime for Maintenance: Standard screens require frequent shutdowns for deck cleaning, panel replacement, and bearing lubrication. This unplanned downtime halts your entire processing line.
High Operational & Replacement Costs: Inefficient screening forces downstream equipment to work harder, increasing wear on crushers and conveyors. Premature failure of screen components creates a cycle of high spare part expenditures.
Inconsistent Product Gradation: Variable feed rates and composition lead to inconsistent sizing, compromising the quality and market value of your metallurgical or foundry coke.

Are you searching for a screening solution that delivers consistent throughput with minimal intervention? Can your operation afford the hidden costs of inefficient particle separation?

2. PRODUCT OVERVIEW

The Commercial Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the rigorous dry separation of furnace coke, nut coke, and coke breeze in bulk handling facilities. It is designed to handle abrasive materials at high temperatures with maximum availability.

Operational Workflow:
1. Controlled Feed: Sized coke from the crusher or cooler is conveyed onto the screen's feed box for even distribution across the width of the deck.
2. HighEfficiency Separation: A powerful dualvibrator motor assembly drives a linear or elliptical motion (model dependent), stratifying material and aggressively conveying it across robust screen panels with precise apertures.
3. Accurate Sizing Split: Onsize particles pass through the deck apertures as product (e.g., +25mm furnace coke), while oversize material is discharged at the deck end for recirculation or further processing. Multiple decks can be configured for multifraction separation.

Application Scope: Primary and secondary sizing of metallurgical coke, foundry coke, and anodegrade carbon materials in coke plants, steel mills, and bulk port facilities.

Limitations: Not designed for wet screening applications or for materials with extreme moisture content that promotes pastelike consistency. Maximum feed temperature is modelspecific but typically rated for materials up to 150°C.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin, pretensioned polyurethane or rubber panel design | Operational Benefit: Panels can be replaced individually in under 15 minutes without specialized tools, drastically reducing maintenance windows. | ROI Impact: Cuts planned maintenance labor hours by up to 60% versus bolteddown steel deck systems.

Advanced AntiBlinding System | Technical Basis: Independently driven ball tray or urethane wiper assemblies located beneath each screen panel | Operational Benefit: Continuous percussive action dislodges lodged particles, maintaining open screen area and consistent throughput. | ROI Impact: Sustains rated capacity, eliminating costly production drops of 1530% common with blinded conventional screens.

DustEncapsulated Vibrator Motors | Technical Basis: IP66rated protection with labyrinth seals on bearing housings | Operational Benefit: Seals out fine coke dust (breeze), the primary cause of premature bearing failure in vibratory equipment. | Operational Benefit: Extends bearing service life by a factor of 3x4x compared to standard designs.

HuckBolt® Frame Construction | Technical Basis: Aircraftgrade hightensile fasteners instead of traditional welding on major frame joints | Operational Benefit: Eliminates stress fractures and frame fatigue failures caused by constant dynamic loading. | ROI Impact: Provides a structural lifetime exceeding 60,000 hours, removing the risk of catastrophic frame failure and associated weekslong downtime.

Variable Frequency Drive (VFD) Compatibility | Technical Basis: Standardized motor windings and control interfaces for optional VFD integration | Operational Benefit: Allows operators to finetune vibration amplitude and frequency to match specific feed conditions (e.g., wetter feedstock) in realtime from the control room.| ROI Impact: Optimizes efficiency for varying conditions; field data shows a 510% reduction in energy consumption under partial load conditions.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Commercial Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Deck Panel Change Time | 48 hours (full deck) | <2 hours (full deck) | Up to 75% faster |
| Screening Efficiency (for target fraction)| ~8590% under optimal conditions| Consistently >95% maintained| +510% sustained yield |
| Bearing Mean Time Between Failure (MTBF)| ~8,000 12,000 hours| Rated >40,000 hours| Over 300% improvement |
| Operational Availability| 9092% (factoring downtime)| Designed for >96% availability| +46% more production time |
| Energy Consumption per Ton Screened| Baseline (100%)| Estimated at 8590% of baseline| 1015% reduction |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: CVR Series; Throughput from 200 TPH to over 1,500 TPH depending on aperture size and material density (coke bulk density ~0.5 – 0.7 t/m³).
Power Requirements: Dual vibrator motors from 2 x 7.5 kW up to 2 x 45 kW; Standard supply: 400/690VAC, 50/60 Hz.
Material Specifications:
Deck Frames & Side Plates: Abrasionresistant steel (AR400).
Screen Panels: Optional hightensile woven wire mesh or modular polyurethane/ rubber panels.
Main Frame & Springs: Heavyduty structural steel with composite rubber spring isolators.
Physical Dimensions: Singledeck units range from 1.8m wide x 4.8m long to 3.6m wide x 9.6m long.
Environmental Operating Range: Ambient temperature from 20°C to +45°C; Handles material temperatures up to +150°C continuously.

6. APPLICATION SCENARIOS

[Steel Mill Coke Handling Plant] | Challenge: A major integrated steel mill experienced chronic blinding on its final product screens after coke cooling, leading to a daily loss of ~200 tons of onspec furnace coke reporting to the breeze bunker as waste.| Solution:| Installation of two CVR2448 Commercial Coke Vibration Screens equipped with polyurethane decks and integrated antiblinding systems.| Results:| Screening efficiency stabilized at ≥96%. Recovered product value paid for the screens in under nine months through reduced waste generation.

[Commercial Coke Producer MultiGrade Facility] Challenge: The need to switch between producing different nut coke sizes (e.g., between 30+20mm and 20+10mm) required fullday shutdowns for manual deck changes on old screens.| Solution:| Implementation of modulardeck CVR screens with a pretensioned panel system.| Results:| Product changeover time reduced from >8 hours to under two hours per screen line directly increasing plant flexibility allowing more spotmarket production runs

7 COMMERCIAL CONSIDERATIONS

Our Commercial Coke Vibration Screens are offered under three primary tiers:

1\. Base Equipment Package Includes fully assembled screen dust encapsulated vibrators standard AR400 wear liners composite spring isolators

2\. Optional Feature AddOns
Modular Polyurethane/Rubber Deck System
Integrated AntiBlinding Units
Variable Frequency Drive Package
Skid Mounting / Integral Feed Hopper
Customized Discharge Hoods

3\. Service Packages
Extended Warranty Plans covering parts/labor
Scheduled Inspection Programs
24/7 Priority Parts Kitting Service

Financing Options Flexible capital equipment financing operating leases are available through our partners enabling you preserve working capital while upgrading critical infrastructure

FAQ

Q What existing foundation requirements does this equipment have?
A Our Commercial Coke Vibration Screens are designed as dropin replacements requiring similar if not identical civil foundations as most legacy units We provide full foundation load drawings during quotation

Q How does this screen handle variations in feed rate?
A The robust design maintains performance across typical surge loads For extreme variations we recommend pairing with an optional VFD package which allows dynamic adjustment maintaining optimal stratification/separation efficiency

Q Are spare parts readily available?
A Yes We maintain strategic inventories all critical wearing components including vibrator motors bearings panel modules Our service network guarantees dispatch within specified response times detailed our service level agreements

Q What typical installation commissioning timeline should we expect?
A From delivery site installation mechanical/electrical hookup dry commissioning typically requires days not weeks We provide comprehensive IOM manuals site supervision available ensure minimal disruption your operations

Q Can these screens be integrated into our existing PLC/SCADA system?
A Yes All units come standard equipped junction boxes remote monitoring points vibration sensors ready integration into plant control systems We provide necessary signal documentation protocols