1. PAINPOINT DRIVEN OPENING

Is your coke handling operation plagued by persistent bottlenecks and quality control issues? For plant managers overseeing coke screening, common challenges directly impact throughput and profitability. Excessive fines contamination in product streams can lead to customer rejections and revenue loss. Frequent screen cloth blinding from sticky, highmoisture coke drastically reduces effective screening area, forcing premature shutdowns for manual cleaning. The constant impact abrasion from bulk coke leads to rapid wear of screen decks and components, generating high replacement part costs and unplanned maintenance windows. Vibration isolation failures transfer destructive forces to support structures, creating longterm integrity concerns and safety risks. How do you maintain specified size fractions consistently while extending equipment service life and maximizing plant uptime? The efficiency of your downstream blast furnace or smelting operation depends on the reliability of this critical separation stage.

2. PRODUCT OVERVIEW

The Coke Vibration Screen is a heavyduty, highamplitude screening machine engineered for the scalping and precise size classification of metallurgical coke, petroleum coke, and foundry coke. Its design prioritizes durability and material throughput in harsh, abrasive environments.

Operational Workflow:
1. Feed & Distribution: Bulk coke is fed onto the robust feed box, which evenly distributes the material across the full width of the primary screen deck.
2. HighEnergy Separation: The exciter drive generates a powerful linear or elliptical motion, aggressively conveying coke along the deck while forcing undersized particles through the screen apertures.
3. Fractional Discharge: Correctly sized product (oversize) discharges from the deck's end, while fines (undersize) pass through to a lower collection chute or subsequent deck for further grading.

Application Scope: Primary sizing of ovendischarged coke, removal of breeze (fines) from blast furnace feed, classification of recirculated coke in sinter plants, and dedusting applications.

Limitations: Not designed for ultrafine screening (8%) may require predrying or heated deck options.

3. CORE FEATURES

HeavyDuty Box Beam Deck Frame | Technical Basis: Reinforced structural steel construction with internal crossbracing | Operational Benefit: Resists deformation under extreme load shock from large coke pieces, maintaining screen cloth tension and preventing premature fatigue failure | ROI Impact: Reduces structural repair downtime by up to 60% and extends overall frame service life by multiple years.

AntiBlinding Ball Tray & Heated Decks (Optional) | Technical Basis: Rubber balls bouncing beneath the screen mesh dislodge lodged particles; thermostatically controlled electric heating elements reduce moisture adhesion | Operational Benefit: Maintains nearoriginal open screening area by preventing aperture blockage, ensuring consistent capacity and product grading | ROI Impact: Improves effective screening efficiency by 2540%, reducing frequency of manual cleanouts and associated labor costs.

DustEncapsulated Vibrator Units | Technical Basis: Labyrinth seals and pressurized grease purge systems prevent fine coke dust ingress into bearing assemblies | Operational Benefit: Protects critical drive components from abrasive contamination, the leading cause of bearing seizure and exciter failure | ROI Impact: Extends vibrator service intervals by over 300%, minimizing lubricationrelated maintenance stops.

Modular Screen Panel System | Technical Basis: Individually clamped polyurethane or rubbercoated steel panels with varied aperture designs | Operational Benefit: Allows for rapid panel replacement (<4 hours vs. full deck changeout) and easy configuration changes for different product specifications | ROI Impact: Cuts panel changeover downtime by 70% and reduces inventory costs through standardized panel sizing.

DualSpring Isolation System | Technical Basis: Multistage isolation with highcycle steel coil springs combined with rubber buffers | Operational Benefit: Absorbs over 95% of dynamic forces, preventing transmission to the supporting structure and minimizing foundation stress cracks | ROI Impact: Eliminates costly structural reinforcement projects and reduces ambient vibration for surrounding equipment.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime)| 9294% due to frequent cloth changes & bearing issues| >96% via antiblinding systems & sealed vibrators| +35% more productive hours annually |
| Screen Cloth Service Life| 46 weeks in primary sizing duty| 812 weeks with modular polyurethane panels & ball trays| +80100% longer lifespan |
| Energy Consumption per Ton| Baseline (100%) for standard bruteforce exciters| Optimized drive kinematics matched to material flow| 15% reduction per ton screened |
| Maintenance ManHours/Month| 2025 hours for lubrication, adjustments, cleanup| <12 hours with centralized lube points & access platforms| ~50% reduction in routine labor |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models from 500 to 2,500 tonnes per hour (TPH), depending on aperture size and feed gradation.
Drive Power: Electromechanical exciters from 15 kW to 75 kW; configured for linear or elliptical throw as required.
Deck Configuration: Single or double deck; widths from 1.8m to 3.6m; lengths from 4.8m to 7.2m.
Screen Media: Heavyduty rubbercoated wire mesh or tensioned polyurethane panels; aperture sizes from 5mm to 80mm.
Construction Materials: Mainframe: ASTM A36 carbon steel; Abrasion zones lined with AR400 steel (10mm); Corrosion protection via industrialgrade epoxy coating.
Operating Environment: Designed for ambient temperatures from 20°C to +50°C; dusttight enclosures available for indoor installation; IP65 rating on electrical components.

6. APPLICATION SCENARIOS

[Integrated Steel Plant] | Challenge: Excessive coke breeze (<10mm) in blast furnace charge was increasing reductant consumption and disrupting burden permeability.Solution: Installation of a primary Coke Vibration Screen with dual decks (25mm top / 10mm bottom) at the battery discharge station.Results: Achieved consistent furnace feed with <3% fines content, leading to a documented 5% reduction in coke rate (kg/THM) and improved gas utilization.

[Petroleum Coke Handling Terminal] ] Challenge: Severe blinding of screens handling highmoisture calcined petcoke caused hourly capacity drops of over 30%, requiring constant operator intervention.Solution: Implementation of a heateddeck Coke Vibration Screen system with thermostatic control.Results: Eliminated moisturerelated blinding entirely, stabilizing throughput at design capacity of 1,200 TPH and reducing daily cleanout labor by two fulltime equivalent positions.

7. COMMERCIAL CONSIDERATIONS

Our Coke Vibration Screens are offered in three capability tiers:
Standard Duty Tier: For lowercapacity (<800 TPH) operations with consistent feed moisture.
HighAvailability Tier: Includes antiblinding systems sealed vibrators extended warranty on drive components recommended for continuous process lines
Custom Engineered Tier: Designed for unique space constraints extreme abrasion profiles or multiproduct separation duties

Optional features include integrated spray bars dust suppression covers variable frequency drives for stroke adjustment overload protection sensors

We offer comprehensive service packages ranging from annual inspection contracts to fullsite managed maintenance including guaranteed parts availability within industryleading timeframes Financing options including leasetoown programs are available which can preserve capital budgets

8.FAQ

Q1 Is your Coke Vibration Screen compatible with our existing feed conveyor discharge height?
A1 Our engineering team requires your current conveyor tail section dimensions We design adjustable base frames or transition chutes as needed ensuring a fitforpurpose installation

Q2 What is the expected impact on our operational noise levels?
A2 Field data shows sound pressure levels typically range between dB(A) at meters due to encapsulated drives spring isolation Properly installed units often meet stringent plant noise standards

Q3 Can you guarantee specific separation efficiency percentages?
A3 Screening efficiency is a function of feed material characteristics aperture shape dwell time We provide performance predictions based on a sample test using our pilotscale unit giving you databacked expectations before purchase

Q4 What are standard payment terms delivery lead times?
A4 Standard commercial terms involve progress payments against milestones Lead times vary by model complexity typically ranging from weeks exworks Expedited production may be available

Q5 How does your pricing compare against refurbishing our existing screens?
A5 We provide Total Cost Ownership analyses comparing rebuild costs projected availability gains energy savings Our solutions often show payback periods under months when factoring increased throughput reduced maintenance