1. PAINPOINT DRIVEN OPENING

Is your coke handling operation plagued by persistent inefficiencies that erode profitability? For plant managers and engineering contractors, the screening phase is a critical bottleneck with direct consequences.

Blinding & Carryover: Moisture and fine coke particles blind traditional screens, reducing effective screening area. This leads to undersized material contaminating your product stream or oversized particles damaging downstream crushers, causing unplanned maintenance.
Excessive Downtime & Maintenance: Conventional screens with complex drive mechanisms and numerous bearings require frequent lubrication and are prone to failure. Each hour of unscheduled downtime represents significant lost production revenue.
Inefficient Separation & Product Inconsistency: Inconsistent feed rates or particle distribution result in poor grade control. Are you facing rejections or price penalties due to product not meeting precise size specifications?
Structural Fatigue & Premature Wear: The abrasive nature of coke accelerates wear on screen decks and side plates. Premature replacement of these components is a recurring capital expense.
High Energy Consumption for Limited Output: Older screening technology often operates at a fixed, high energy draw regardless of load, leading to inefficient power use per ton of material processed.

The question becomes: how do you achieve reliable, consistent coke classification while controlling operational costs and maximizing equipment uptime?

2. PRODUCT OVERVIEW

The Custom Coke Vibration Screen is a heavyduty, linear motion vibrating screen engineered specifically for the harsh demands of coke sorting and sizing operations. It separates raw or processed coke into two or more precise fractions based on particle size.

Operational Workflow:
1. Controlled Feed: Coke is fed onto the inlet head of the screen via a conveyor or feeder.
2. Stratified Separation: The highGforce linear vibration stratifies the material bed, forcing fines downward through the apertures of the robust screen deck panels.
3. Efficient Conveyance: The linear motion efficiently conveys oversize material along the deck length to the discharge end.
4. Clean Split: Properly sized undersize material passes through the deck, while oversize continues to the designated discharge spout.
5. Continuous Operation: The system operates continuously under heavy load with minimal performance degradation.

Application Scope: Sizing of foundry coke, metallurgical coke (metcoke), petroleum coke (petcoke), and anodegrade coke in quenching stations, blast furnace feed lines, and calcining plants.

Limitations: Not designed for sticky, highly cohesive materials without pretreatment or specialized deck technology. Maximum efficiency requires controlled, even feed distribution across the full screen width.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin, panelized design with multiple tensioning options | Operational Benefit: Allows for rapid panel changeout during planned maintenance; decks can be customized with different aperture sizes/types (wire mesh, polyurethane, perforated plate) for specific cuts | ROI Impact: Reduces deck replacement downtime by up to 60% compared to welded systems

HeavyDuty Vibrator Assembly | Technical Basis: Twin counterrotating eccentric shafts generating synchronized linear motion | Operational Benefit: Delivers consistent, adjustable stroke for optimal material stratification and conveyance; sealedforlife bearings eliminate routine lubrication points | ROI Impact: Lowers annual maintenance labor hours by approximately 30% and removes risk of lubricationrelated failures

AbrasionResistant Lining Package | Technical Basis: Wear plates manufactured from AR400 steel or equivalent at all critical contact points (feed box, side liners) | Operational Benefit: Protects the main frame structure from abrasive wear, extending the machine's structural service life by several years | ROI Impact: Defers major capital expenditure on screen body replacement; reduces annual wear part costs

Controlled Vibration Isolation | Technical Basis: Highperformance rubber or coil spring isolators calculated for dynamic load | Operational Benefit: Absorbs over 95% of dynamic forces before they transfer to the supporting structure, preventing structural fatigue in buildings and feed platforms | ROI Impact: Eliminates costly structural reinforcement needs and associated civil engineering work

PLCReady Vibration Monitoring | Technical Basis: Integrated ports for accelerometer sensors on bearing housings | Operational Benefit: Enables conditionbased monitoring predictive maintenance programs; provides early warning of imbalance or bearing degradation | ROI Impact: Prevents catastrophic bearing failures that lead to extended downtime and secondary damage; enables maintenance scheduling during production pauses

Optimized Discharge Hood Design | Technical Basis: Computational Flow Dynamics (CFD) modeled hoods with internal baffles | Operational Benefit: Minimizes dust emission at discharge points by controlling air movement; contains material within the chute stream | ROI Impact: Reduces housekeeping labor and improves compliance with plant environmental standards

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Solution | Custom Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (for defined cut point) | 8590% under ideal conditions | Consistent 9296% efficiency across variable feed rates| +58% More Product Yield |
| Annual Bearing Service Interval| Quarterly lubrication required; ~18month replacement common| Sealed vibrator assembly; bearing life expectancy >24 months under load| +300% Service Interval / 100% Lube Costs|
| Deck Panel Replacement Time (for full deck)| 812 hours with cutting/welding| 35 hours using boltin modular system| ~60% Faster Changeout |
| Force Transmission to Support Structure| Up to 40% transmitted dynamic force|<5% transmitted dynamic force via optimized isolation| 87.5% Structural Stress |
| Energy Consumption per Ton Processed| Baseline (100%) reference value| Field data shows reduction through efficient drive design & load adaptation.| 1015% Lower kWh/ton |

5. TECHNICAL SPECIFICATIONS

Capacity & Rating: Modeldependent capacities from 200 to 2,500 TPH of dry coke. Designed for continuous 24/7 operation with an operational availability factor exceeding 98%.
Power Requirements: Driven by dual vibrator motors ranging from 7.5 kW to 45 kW total installed power (400V/50Hz or other specified). IP66 protection rating standard.
Material Specifications:
Main Frame & Side Plates: Mild steel (ST37), shotblasted and primed.
Wear Surfaces & Liners: AR400 AbrasionResistant Steel (minimum).
Screen Decks Options: Highcarbon steel wire mesh (65Mn), polyurethane modular panels (95 Shore A), rubberclad perforated plate.
Fasteners & Hardware:A4/A2 stainless steel standard in critical areas.
Physical Dimensions: Single, double, or tripledeck configurations available. Standard widths from 1.2m to 3.6m; lengths from 4m to 10m.
Environmental Operating Range: Ambient temperature range from 20°C to +50°C suitable for outdoor installation with optional weather covers.

6. APPLICATION SCENARIOS

Metallurgical Coke Plant – Blast Furnace Feed Line

Challenge:A major steel producer experienced frequent blinding on circular screens handling quenched coke (~8% moisture). This caused inconsistent sizing feeding their blast furnaces (~25mm cut), leading to irregular furnace operation and increased fuel rate.Solution:The installation of a custom linear motion vibration screen equipped with nonblinding polyurethane tensioned decks designed specifically for damp materials.Results: Screening efficiency stabilized at >94%. Carryover of fines was reduced by over 80%. Plant engineers reported a measurable improvement in blast furnace consistency within one month.

Calcined Petroleum Coke Facility – Final Product Sizing

Challenge:The final sizing stage for anodegrade CPC required an extremely clean separation at multiple cut points (e.g., 4mm +1mm). Existing screens generated excessive dust (1mm fraction) due to poor stratification.Solution:A custom tripledeck vibration screen was implemented featuring fully enclosed dusttight housings on each deck discharge.Results:Product purity improved significantly,directly impacting sales pricing.Dust emissions at the screening station were contained,and recovered ultrafines were captured as a separate,salable product stream,increasing overall plant yield.

7.COMMERCIAL CONSIDERATIONS

Pricing tiers are structured based on machine size,material specification,and customization level:
• Standard Series(12m width):For lowercapacity circuits.Recommended for pilot plants/satellite facilities.Optional features include basic wear liners&standard motor mounts.• HeavyDuty Series(23m width):The most common tier,focused on maximum durability.Includes AR400 liners as standard,vibration monitoring ports,&heavyduty isolators.• Premium Engineered Series(3m+ width):Fully customized solutions.Includes CFDmodeled hoods,custom alloy liners(Hardox® etc.),full instrumentation packages,&dedicated engineering support during commissioning.Service Packages:
• Basic Warranty:Covers parts&labor for12 months.• Extended Support Plan(3/5 years):Includes annual inspection,vibration analysis reports,&discounted spare parts.• FullService Maintenance Agreement:Covers all scheduled&unscheduled maintenance performed by certified technicians.Financing Options:
Capital expenditure can be structured through equipment leasing programs,tailored rentaltoown agreements,&projectbased financing solutions subjectto credit approval.This allowsforopexbasedbudgetingandtechnologyupgradeswithoutlargeinitialoutlay.

8.FAQ

Q:What if my existing foundation isn't designed fora vibrating screen?
A:The highefficiency isolation system drastically reduces dynamic loads transferred.We provide detailed foundation loading drawings specificto your model,and our engineering team can review existing structuresfor retrofit feasibility.Q:What about compatibilitywith my existing PLC/DCS system?
A:The vibration monitoring system provides standard420mA outputsor Modbus RTU signals that can be integrated into most plant control systemsfor realtime health monitoring.Q:What isthe typical lead timefora custom unit?
ALead times varybycomplexity.For standard HeavyDuty Series models,the lead timeis typically14–16 weeksfromorder approvalto shipment.Q:What spare parts should I stock?
AWe recommend maintaining an initial inventoryof critical wear items:specificdeck panels(for your cut size),a setof vibrator mounting bolts,and isolator springs.This minimizes potential waiting timefor consumable parts.Q:Doyou offer onsite installation supervision?
AYes.Commissioning supportand onsite supervisionare availableas partof our service packages.This ensures proper installation alignmentand operational setupby qualified personnel.Q:Canyour screens handle hot coke?
AYes,but this requires specific design considerations including heatresistant seals,bearingswith hightemperature grease,&potentially special deck materials.We offer designs ratedfor material temperatures up too180°C.Q:What factors determine whether touse wire mesh,polyurethane.or rubber decks?
ADeck selection depends on cut size,material abrasiveness.moisture content,&required service life.Wire mesh offers excellent open area but shorter life.Polyurethane resists blinding&wear.Rubber excelsin noise reduction&handling large lump sizes.We provide guidance basedon your application data