1. PAINPOINT DRIVEN OPENING

Is your coke processing line struggling with persistent bottlenecks and quality control issues at the screening stage? Inefficient particle separation directly impacts product purity, yield, and downstream operations. Common challenges include:

Blinding & Carryover: Moisture and fine coke particles clog screen apertures, reducing effective screening area and forcing material to bypass the process, contaminating finished product.
Excessive Downtime & Maintenance: Frequent screen deck replacements and bearing failures due to highimpact loads from coke create unplanned stoppages, costing hundreds of production hours annually.
Inconsistent Grade Separation: Inadequate vibration dynamics or screen deck design lead to missized material passing through, resulting in offspec product that fails to meet stringent client metallurgical coke specifications.
Structural Fatigue & Failure: The abrasive nature of coke accelerates wear on machine components, while inadequate structural design leads to cracking in side plates and decks under continuous heavyduty operation.

Are you seeking a screening solution that delivers consistent grade separation, withstands the abrasive environment of coke handling, and operates with minimal intervention?

2. PRODUCT OVERVIEW: HeavyDuty Coke Vibration Screen

This equipment is a highcapacity, linear motion vibrating screen engineered specifically for the sizing and scalping of metallurgical and fuel coke. It separates crushed coke into precise fractions—such as blast furnace nut coke, breeze, or larger fractions—critical for downstream processing or final product stockpiling.

Operational Workflow:
1. Feed & Distribution: Crushed coke is fed onto the robust feed box, which evenly distributes the material across the full width of the upper screen deck.
2. Stratified Separation: Dual counterrotating vibrator motors generate a linear throwing motion. This action stratifies the material bed, allowing finer particles to sift down through multiple screen decks with defined aperture sizes.
3. Fraction Discharge: Correctly sized material passes through each deck, while oversize travels along the deck length. Discrete chutes discharge each separated fraction (e.g., oversize, midsize/nuts, fines/breeze) for further processing or shipment.

Application Scope: Primary sizing of crushed coke (wet or dry), scalp removal of oversized material postcrusher, dedusting (breeze removal). Not designed as a replacement for thermal dryers or for materials with extreme adhesive properties without modification.

3. CORE FEATURES

Modular Deck System | Technical Basis: Boltin, pretensioned polyurethane or rubber clad steel panels | Operational Benefit: Panels can be replaced individually in under 30 minutes without welding or specialized tools. Different panel types can be fitted per deck for specific wear or blinding resistance. | ROI Impact: Reduces screen media change downtime by up to 70% compared to welded systems, lowering labor costs and inventory complexity.

Dual CounterRotating Vibrator Assembly | Technical Basis: Two synchronized vibrator motors generating a linear force vector; labyrinth seals & highgrade bearings. | Operational Benefit: Delivers consistent, adjustable stroke for optimal material stratification and travel speed. Sealed design prevents lubricant contamination from coke dust. | ROI Impact: Field data shows a 40% increase in bearing service life over standard units in abrasive environments, reducing spare part costs and failure risk.

AbrasionResistant Lining Package | Technical Basis: Wear plates manufactured from AR400 steel at all critical impact points (feed box, discharge lips). | Operational Benefit: Protects the main frame structure from direct abrasion by coke particles, preserving structural integrity over decades of service. | ROI Impact: Eliminates the need for frequent weld repair on the main frame body, a major source of longterm maintenance cost in coke screening.

Optimized Dynamic Tuning | Technical Basis: Finite Element Analysis (FEA) validated main frame design with tuned spring isolation system. | Operational Benefit: Maximizes vibration energy directed to the screen decks for efficiency while isolating destructive forces from the support structure; reduces transmitted vibration to the building. | ROI Impact: Increases structural lifespan and allows installation on elevated platforms without costly structural reinforcement.

Environmental Sealing System | Technical Basis: Multistage dust sealing between decks and side plates using durable rubber seals. | Operational Benefit: Significantly reduces emission of fine coke breeze (PM) into the plant environment during operation. | ROI Impact: Lowers housekeeping costs and supports compliance with plant environmental health standards.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard | Our Coke Vibration Screen Solution | Advantage (% improvement) |
| : | : | : | : |
| Screen Deck ChangeOut Time| 812 hours (welded) | 23 hours (modular boltin) | ~70% faster |
| Bearing Life in Coke Service| ~8,000 hours| 12,000+ hours| +40% |
| Structural Fatigue Life (to first crack)| 57 years| 10+ years| +80% |
| Screening Efficiency (grade purity)| 8590% consistency| 9497% consistency| +7% absolute gain |
| Energy Consumption per Ton Screened| Baseline (100%)| Optimized drive & mass balance reduces draw by ~15%| 15% reduction |

5. TECHNICAL SPECIFICATIONS

Capacity & Rating: Designed for throughputs from 200 to 2,500 TPH depending on model size and separation duty.
Power Requirements: Dual vibrator motors ranging from 2 x 7.5 kW to 2 x 55 kW (400/690V, 50/60Hz). Total installed power varies by model.
Material Specifications: Main frame: Heavyduty carbon steel plate with reinforced ribs. Wear surfaces: AR400 steel liners standard; optional HARDOX® equivalents available.
Physical Dimensions: Widths from 1.2m to 3.6m; lengths from 4.8m to 10m; multiple deck configurations (13 decks).
Environmental Operating Range: Ambient temperature range: 20°C to +45°C. Suitable for outdoor installation with standard IP65 protection on electrical components.

6. APPLICATION SCENARIOS

[Steel Plant Blast Furnace Feed Preparation] Challenge: A major integrated steel mill experienced inconsistent nut coke sizing (2575mm). Fines were entering the blast furnace charge due to screen blinding from residual moisture after quenching.

[Solution Coke Vibration Screen Implementation]: A customdesigned linear screen featuring nonblinding polyurethane screen panels on the top deck was installed postquenching station.

[Results Quantifiable Outcomes]: Achieved consistent nut coke purity >96%, reducing blast furnace dust carryover by an estimated 18%. Screen panel service life increased from 3 months to over 14 months.

[Coke Production Facility Product Classification] Challenge: A merchant coke producer needed to separate three distinct product grades simultaneously but faced excessive downtime due to rapid wear on traditional wire mesh panels.

[Solution Coke Vibration Screen Implementation]: A tripledeck vibrating screen was supplied with a combination of rubberclad panels on upper decks for abrasion resistance and tensioned polyurethane panels on lower decks for fine separation.

[Results Quantifiable Outcomes]: Plant output increased by 22% due to reduced changeout downtime combined with higher throughput capability achieved via improved stratification action.

7. COMMERCIAL CONSIDERATIONS

Pricing Tiers: Pricing is modeldependent based on size/deck count:
Tier I (1500 TPH): Extraheavyduty construction
Optional Features / Upgrades: Hot material screens (<120°C), explosionproof motor specifications for certain zones , spray bar systems for washing/dust suppression , advanced condition monitoring sensors .
Service Packages Offered:

1.Preventive Maintenance Kit
2.OnSite Training Package
3.Extended Warranty Plan

Financing Options Available:
1.Equipment Leasing
2.RentaltoOwn Programs

8.FAQ

Q1:What is your approach towards technical compatibility when integrating this new vibrating screen into an existing crushing circuit?
A1:A detailed review process includes analysis of your current feed chute design,surge bin capacity,and conveyor discharge heights.This ensures proper interfacing without requiring major modifications unless absolutely necessary.The goal is plugandplay integration where possible .

Q2:What operational impact should our shift managers expect during commissioning?
A2:The primary operational adjustments will involve tuning vibration amplitude/frequency via motor weights/rotation speed settings,and adjusting feed rate parameters.We provide comprehensive onsite training so your team can confidently operate within optimal parameters within days .

Q3:What are typical lead times,and what factors influence them?
A3:A standard unit typically has an eighttotwelve week lead time.Customizations such as special materials coatings,dust enclosures,and nonstandard electrical voltages may extend this timeline slightly.A firm schedule will be provided upon finalization .

Q4:What commercial terms do you offer regarding payment structure?
A4:A standard commercial arrangement involves thirty percent down payment upon order placement,fifty percent prior shipment,and twenty percent balance due upon successful commissioning.This structure helps manage cash flow effectively throughout project execution phases .

Q5:What does implementation support typically include?
A5:The implementation package includes supervision during installation,vibrational alignment checks,lubrication procedures training,and initial performance testing.We remain available remotely until full production capacity has been reached according agreed metrics .

Q6:What are common reasons behind premature failure seen elsewhere that this design addresses specifically?
A6:The two most common causes are structural fatigue at weld joints due improper dynamic tuning leading stress concentrations,and bearing ingress contamination leading premature seizure.This equipment utilizes FEAtuned structures along sealed vibrator assemblies specifically mitigate these pointsoffailure .

Q7:What kind performance guarantee do you provide regarding throughput efficiency grade separation accuracy ?
A7:A performance guarantee covering guaranteed minimum throughput tonnage under specified conditions along guaranteed screening efficiency percentage will be detailed within contract documentation prior commencement manufacturing .