1. PAINPOINT DRIVEN OPENING

Is your coke handling operation struggling with persistent bottlenecks and escalating costs? For plant managers overseeing coke screening, common challenges directly impact profitability and uptime. Excessive fines generation due to aggressive screening action can degrade product value. Frequent screen cloth blinding from moist or sticky material leads to constant manual cleaning, halting the line. Unplanned downtime for deck replacements or structural repairs creates costly production gaps. High vibration transmission to the support structure accelerates wear on surrounding infrastructure, increasing maintenance overhead. Are you facing rising operational costs, inconsistent product grading, and unreliable throughput in your classification process? The efficiency of your downstream processes depends on the performance of your primary screening equipment.

2. PRODUCT OVERVIEW

The Custom Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the precise dry separation of metallurgical coke and petroleum coke. Its design focuses on durability and consistent performance in harsh, abrasive environments typical of coke handling plants.

Operational Workflow:
1. Feed Introduction: Bulk coke is fed uniformly onto the feed box of the Custom Coke Vibration Screen.
2. Stratification & Separation: A highGforce linear or elliptical motion stratifies material rapidly; sized particles pass through precisely tensioned screen decks.
3. Product Discharge: Correctly sized coke (e.g., blast furnace coke, nut coke) is discharged via designated chutes, while oversize material is separately conveyed for potential crushing.

Application Scope: Primary sizing of hot or cold coke, dedusting (removal of breeze), scalping of oversized material ahead of crushers.
Limitations: Not designed for wet screening or slurry applications. Optimal performance requires controlled feed rates and specific moisture content parameters to prevent blinding.

3. CORE FEATURES

Modular Deck System | Technical Basis: Independent, boltin panel design with side tensioning rails | Operational Benefit: Allows for rapid replacement of individual screen panels without full deck disassembly, minimizing downtime for cloth changes | ROI Impact: Reduces screen media changeout time by up to 60%, directly increasing plant availability.

Advanced AntiBlinding Systems | Technical Basis: Integrated ball tray decks or flexible polyurethane cleaning rings | Operational Benefit: Continuous microimpact dislodges particles trapped in screen apertures, maintaining nearoriginal open area and screening efficiency | ROI Impact: Sustains rated throughput and product quality, reducing yield loss from misdirected fines by an average of 1525%.

DualVibration Motor Drive | Technical Basis: Two synchronized externally mounted motors generating linear vibration | Operational Benefit: Provides consistent, adjustable Gforce without complex mechanical drives; simplified maintenance with offtheshelf motor components | ROI Impact: Lower lifecycle maintenance costs compared to singleshaft eccentric drives; field data shows a 30% reduction in drive system maintenance hours.

Isolated Vibration Frame | Technical Basis: Rubber shear mounts or coil spring isolators between the vibrating body and base frame | Operational Benefit: Absorbs over 95% of dynamic forces, preventing transmission to the supporting structure | ROI Impact: Eliminates structural fatigue damage, extending the service life of support steelwork and foundations, reducing longterm capital repair costs.

HeavyDuty Construction Specs | Technical Basis: AR400 abrasionresistant steel liners at feed points, reinforced side plates with continuous welding | Operational Benefit: Withstands continuous impact from abrasive coke lumps (25100mm) without premature wearthrough or structural cracking | ROI Impact: Extends major overhaul intervals; documented case studies show structural service life exceeding 10 years in continuous operation.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Custom Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Screening Efficiency (for defined cut point) | 8590% sustained efficiency before blinding affects output grade. | Maintains 9295% efficiency over extended campaigns due to antiblinding tech.| +8% sustained efficiency |
| Screen Cloth ChangeOut Time (full deck) | 812 hours for bolteddown panels requiring full access dismantling.| 35 hours using modular sidetensioned panels with frontaccess design.| 60% downtime impact |
| Annual Maintenance Cost per tonnage output (drive & structure)| Baseline = 100% (for comparative analysis).| Industry benchmarking indicates average cost reduction to ~70% of baseline.| ~30% cost reduction |
| Transmitted Dynamic Force to Support Structure| Typically 2030% of dynamic force transmitted, causing fatigue.| 80% reduction in transmitted force |

5. TECHNICAL SPECIFICATIONS

Capacity & Rating: Modeldependent capacities from 500 to 2,500 metric tons per hour (MTPH). Designed for continuous 24/7 operation.
Power Requirements: Dual vibration motors ranging from 2 x 7.5 kW to 2 x 30 kW (400/690V, 50/60Hz). Total installed power includes optional onboard dust enclosure vibrators.
Material Specifications: Main frame: S355JR structural steel. Wear liners: AR400 (Brinell 400) at feed zone and discharge lips. Screen decks: Side plates in Hardox 400; compatible with tensioned rubber,polyurethane, or woven wire panels.
Physical Dimensions: Singledeck or multideck configurations; typical widths from 1.8m to 3.6m; lengths from 4.8m to 7.2m.
Environmental Operating Range: Ambient temperature range: 20°C to +50°C.Capable of handling coke temperatures up to ~120°C with specific deck material selection.Dust protection rating standard IP65 for motors and electrical components.

6. APPLICATION SCENARIOS

[Steel Plant Blast Furnace Feed Preparation] Challenge: A major integrated steel mill experienced inconsistent blast furnace coke sizing (2575mm), leading to irregular gas flow and increased fuel rate.Frequent screen blinding on rainy days caused unscheduled shutdowns.Solution: Installation of two widebody Custom Coke Vibration Screens with polyurethane antiblinding panel systems under covered stockhouse.Results: Achieved consistent product grading with 98%, contributing to a documented 1.5% reduction in blast furnace coke rate.

[Petroleum Coke Calcining Plant] Challenge: A calciner needed efficient separation of highvalue calcined petroleum coke (CPC) into multiple product fractions (4mm,+8mm etc.) but faced rapid wear of screen cloth from abrasive CPC and dust emission issues.Solution: Implementationof a tripledeck Custom Coke Vibration Screen featuring modular ARlined decksand a fully sealed dust enclosure with flanged outlets.Results: Extended screen panel life by approximately40%. Contained over99%of process dust within the system.Metallurgical yield improved through precise cut points,increasing premium fraction output by8%.

7.COMMERCIAL CONSIDERATIONS

Pricing Tiers: Equipment pricing is modelspecific based on size,material specification,and features.Entrylevel standardduty units are available for lowercapacity applications.Premium heavyduty modelswith full abrasion protection represent the core offering for hightonnage plants.

Optional Features: Enclosed dustproof designs,dribble chutes,RipTape® dust sealing systems,variable frequency drivesfor stroke adjustment,intelligent monitoring systemswith vibration sensorsand temperature probes.

Service Packages: Standard packages include commissioning supervisionand operator training.Premium support contracts offer scheduled preventive maintenance inspections,vibrational analysis,and priority accessto spare parts kits.

Financing Options: Flexible commercial terms available through partner financial institutions,includingleasing structuresand leasetoown programsto align capital expenditurewith project cash flow.

8.FAQ

Q:What existing foundation can a Custom Coke Vibration Screen be installed on?
A:The isolated design significantly reduces dynamic loads,making it suitablefor retrofit onto many existing properly designed concrete foundations.A site reviewand dynamic load calculation are recommendedto confirm compatibility.

Q:What is the operational impact on power consumption comparedto older bruteforce screens?
A:The direct vibrator motor driveis highly efficient.Field dataindicates comparableor slightly lower specific energy consumption(kWh per ton)despite higher performance,due toprecise applicationof energyto the screening motion ratherthan driving mechanical linkages.

Q:What arethe commercial termsfor spare parts availability?
A:Critical wear parts(deck modules,motors,rubber isolators)are stockedunder a guaranteed availability programwith defined delivery schedules( e.g.,48hrs formotors).This minimizes operational riskfrom unplanned stoppages.

Q:What levelof operator trainingis required?
A:The design emphasizes operational simplicity.Training focuseson daily visual checks,routine greasing procedures,andthe safe lockout/tagout processfor panel changes.Typical training requiresone shiftfor operations staffand one dayfor maintenance personnel.

Q:What isthe lead timefor a customconfigured unit?
A:Lead timesvaryby complexity.For standard sizeswith common options,the lead timeis typically1418 weeksfrom order approvalto exworks readiness.Nonstandard designsrequire additional engineering time.

Q:Canyour screens handle other materialsbesides metallurgicaland petroleumcoke?
A:The core technologyis suitedfordry,sized classificationof granular materials.Equipment canbe engineeredforsimilar applicationslike sinterfeed,sized iron ore pelletsor aggregates,but specificationsmustbe reviewedper applicationdue todifferencesin abrasiveness,density,and particle shape