White Label Coke Vibration Screen Brochure

The Cost of Inefficient Coke Screening: Are You Losing Margin on Every Ton?

Coke producers and processors face persistent operational challenges that directly impact profitability. Fugitive dust emissions from traditional screening equipment can exceed 50 mg/Nm³, triggering regulatory penalties and increasing maintenance frequency. Blinding and pegging of screen media in sticky coke applications causes throughput reductions of 1525%, forcing unscheduled downtime every 7296 hours. Screen deck wear from abrasive coke particles accelerates replacement cycles to 68 weeks, with each changeover costing $4,000$8,000 in lost production and labor. Inconsistent particle size distribution—particularly the critical +25mm and 6mm fractions—leads to rejected shipments and customer penalties averaging $1218 per ton. High noise levels (95105 dB) from conventional screens create OSHA compliance risks and operator fatigue.

Can your current screening solution maintain consistent cutpoint accuracy at 200 TPH while controlling dust below 10 mg/Nm³? Are you replacing screen panels every 45 days when a properly engineered solution could extend that interval to 16 weeks? This brochure presents a white label vibration screen engineered specifically for coke applications, designed to address these exact operational pain points.

Product Overview: HeavyDuty Linear Motion Vibration Screen for Coke Processing

This white label vibration screen is a dualshaft, linear motion vibratory classifier purposebuilt for dry or wet screening of metallurgical coke, petroleum coke, and calcined coke. The equipment operates on a forcedsynchronization principle using two counterrotating vibrator motors mounted at 45° to the screen deck, producing a straightline throw that conveys material across the screening surface while stratifying particles by size.

Operational Workflow:
1. Feed Distribution: Coke material (080mm) enters via a flanged inlet chute, distributed evenly across the full deck width by a feed box with replaceable wear liners (AR400 or ceramic tile).
2. Stratification & Conveyance: Linear motion (68mm amplitude at 8501000 RPM) lifts and tumbles the material bed, allowing fines to contact the screen surface while oversize travels toward the discharge end.
3. Size Separation: Material passes through woven wire, polyurethane, or perforated plate media (custom aperture from 3mm to 50mm). Undersize falls to a collection hopper; oversize exits via a discharge spout.
4. Dust Containment: A bolted, gasketed enclosure with negative pressure ports captures airborne particulates, routing them to a baghouse or wet scrubber.
5. Discharge & Reclaim: Two or three product streams (fines, midsize, oversize) are directed to downstream conveyors or storage bins.

Application Scope: Primary and secondary screening of blast furnace coke, foundry coke, anodegrade petroleum coke, and calcined coke for aluminum smelting. Suitable for dry screening at 36% moisture or wet screening with spray bars (water consumption: 0.51.5 m³/ton).

Limitations: Not recommended for materials exceeding 80°C surface temperature without hightemperature bearing upgrades. Maximum feed moisture for dry screening: 8% (above this, blinding becomes significant). Throughput capacity decreases by 3040% when screening below 3mm aperture.

Core Features

HeavyDuty Vibrator Assembly | Technical Basis: Dualshaft, oillubricated exciter with spherical roller bearings | Operational Benefit: Generates consistent linear motion (610mm stroke) without belt slippage or phase shift, maintaining cutpoint accuracy within ±2% of aperture size | ROI Impact: Reduces rescreening costs by $0.500.80 per ton; extends bearing life to 25,000+ operating hours

Modular Screen Deck System | Technical Basis: Tensioned, boltdown polyurethane or modular polydeck panels with 4060% open area | Operational Benefit: Panel replacement in 23 hours versus 812 hours for traditional wedgewire decks; no welding required | ROI Impact: Reduces annual maintenance labor by 120180 hours; panel life of 1418 weeks in coke service

Integrated Dust Containment Enclosure | Technical Basis: Welded steel housing with continuous gasket seals and negative pressure plenum (0.51.0 in. H₂O) | Operational Benefit: Captures 99.5% of fugitive dust at source; eliminates need for external hoods or shrouds | ROI Impact: Avoids EPA fines of $15,00050,000 per violation; reduces baghouse filter replacement frequency by 40%

Variable Frequency Drive (VFD) Control | Technical Basis: 3phase AC motor (1550 HP) controlled by VFD, adjusting RPM from 6001200 | Operational Benefit: Operators can finetune stroke frequency for varying coke moisture (38%) and feed rates (150300 TPH) | ROI Impact: Energy savings of 1218% versus fixedspeed operation; reduces screen blinding by 35% in wet conditions

Replaceable Wear Liner Package | Technical Basis: AR400 steel or 92% alumina ceramic tiles in feed box, discharge spouts, and sidewall impact zones | Operational Benefit: Wear life of 812 months in highimpact areas versus 34 months for standard mild steel | ROI Impact: Reduces replacement part costs by $6,00012,000 annually; eliminates 23 unscheduled shutdowns per year

QuickRelease Tensioning System | Technical Basis: Pneumatic or hydraulic tensioning rails with camlock mechanisms for screen media | Operational Benefit: Screen media changeover in 45 minutes versus 34 hours with manual bolt systems | ROI Impact: Increases equipment availability by 23%; reduces changeover labor costs by $400600 per event

Integrated Spray Bar Option (Wet Screening) | Technical Basis: Stainless steel spray bars with adjustable nozzles (3060 psi) positioned at 15° angle to deck | Operational Benefit: Removes adhering fines from coke surfaces; reduces dust generation by 90% during wet operation | ROI Impact: Improves product quality by reducing ash carryover; lowers water consumption to 0.8 m³/ton versus 1.5 m³/ton for conventional systems

Competitive Advantages

| Performance Metric | Industry Standard (Conventional Inclined Screen) | White Label Coke Vibration Screen | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (% passing target aperture) | 8590% | 9497% | 810% improvement |
| Screen Media Life (weeks, coke service) | 68 weeks | 1418 weeks | 100125% longer life |
| Dust Emissions (mg/Nm³) | 3555 mg/Nm³ | 512 mg/Nm³ | 7585% reduction |
| Unscheduled Downtime (hours/month) | 814 hours | 24 hours | 6575% reduction |
| Energy Consumption (kWh/ton) | 0.450.65 kWh/ton | 0.320.48 kWh/ton | 2028% lower consumption |
| Noise Level (dB at 1 meter) | 95105 dB | 8288 dB | 1015 dB reduction |
| Changeover Time (screen media) | 34 hours | 45 minutes | 7580% faster |
| CutPoint Accuracy (±% of aperture) | ±5% | ±2% | 60% tighter tolerance |

Technical Specifications

| Parameter | Specification |
| : | : |
| Model Range | WLC1224 (4'x8') to WLC2448 (8'x16') |
| Throughput Capacity | 100350 TPH (depending on aperture and feed size) |
| Screen Area | 32128 ft² (312 m²) |
| Number of Decks | 1 or 2 (customizable) |
| Screen Media Options | Woven wire (304 SS), polyurethane (6090 Shore A), perforated plate (AR400) |
| Aperture Range | 3mm to 50mm |
| Vibration Type | Linear motion, dualshaft exciter |
| Stroke Amplitude | 610 mm (adjustable via eccentric weights) |
| Operating Frequency | 7501050 RPM (VFD controlled) |
| Motor Power | 1550 HP (1137 kW), 460V/3phase/60Hz (or 380V/50Hz) |
| Motor Type | TEFC, IP55, Class F insulation |
| Deck Angle | 0° (horizontal) to 5° (declined) |
| Material of Construction | Carbon steel (A36) or 304 stainless steel (foodgrade coke) |
| Wear Liners | AR400 steel (standard), 92% alumina ceramic (optional) |
| Dust Enclosure | Bolted steel housing, gasketed, with 6" or 8" flanged ports |
| Operating Temperature Range | 20°C to 80°C (standard); up to 150°C with hightemp bearings |
| Maximum Feed Moisture (dry) | 8% |
| Maximum Feed Size | 80mm |
| Overall Dimensions (WLC1836) | 18' L x 6' W x 7' H (5.5m x 1.8m x 2.1m) |
| Total Weight (WLC1836) | 12,500 lbs (5,670 kg) |
| Noise Level | 8288 dB at 1 meter (with enclosure) |

Application Scenarios

Blast Furnace Coke Screening at Integrated Steel Mill | Challenge: A 2.5 MTPA steel plant was experiencing 12% fines carryover (+25mm product contained 8% 6mm material), resulting in rejected shipments and $2.1M annual penalties. Existing inclined screens required weekly media replacement due to abrasive wear. | Solution: Installed two WLC2448 white label vibration screens with polyurethane modular decks (25mm and 6mm apertures) and integrated dust enclosure. VFD tuning optimized stroke for 5.5% moisture coke at 280 TPH. | Results: Fines carryover reduced to 1.2% (below 2% specification). Screen media life extended to 16 weeks. Dust emissions measured at 8 mg/Nm³. Annual penalty costs eliminated; maintenance labor reduced by 180 hours/year. ROI achieved in 11 months.

Petroleum Calcined Coke Sizing for Anode Production | Challenge: An aluminum smelter's calcined coke screening line (150 TPH) suffered from 22% blinding of 4mm aperture screens due to residual volatile matter (0.51.0%). This caused throughput to drop to 110 TPH and required daily manual cleaning. | Solution: Deployed a WLC1836 white label screen with heated deck option (electrical resistance heating to 60°C) and 4mm polyurethane media. VFD set to 950 RPM with 7mm stroke. Spray bar system added for periodic wet cleaning. | Results: Blinding reduced to 3%. Throughput stabilized at 145 TPH. Manual cleaning eliminated. Product size distribution (90% passing 4mm, 95% retained on 0.5mm) met anodegrade specifications. Energy consumption: 0.38 kWh/ton. Payback period: 14 months.

Foundry Coke Reclaim from Stockpile | Challenge: A foundry operation needed to screen 50,000 tons of stockpiled coke (075mm) to produce 25mm x 50mm foundrygrade product. Existing portable screen plant had 65% efficiency and generated excessive noise (102 dB) near residential areas. | Solution: Provided a mobile WLC1224 white label screen on skid base with dieselhydraulic drive (50 HP). Dualdeck configuration: top deck 50mm perforated plate, bottom deck 25mm woven wire. Enclosure with sounddampening panels reduced noise. | Results: Screening efficiency improved to 93%. Noise level reduced to 85 dB at 50 meters. Production rate: 180 TPH. Recovered 42,000 tons of saleable foundry coke from stockpile. Equipment relocated to three sites over 18 months with zero structural issues.

Commercial Considerations

Equipment Pricing Tiers (FOB Factory, USD):

• Standard Package (WLC1224): $48,00062,000 (single deck, carbon steel, woven wire media, manual tensioning)
• Enhanced Package (WLC1836): $78,000105,000 (dual deck, polyurethane media, VFD, dust enclosure, AR400 liners)
• Premium Package (WLC2448): $135,000180,000 (dual deck, ceramic liners, heated deck option, spray bars, pneumatic tensioning, stainless steel construction)

Optional Features:

• Hightemperature bearing upgrade (150°C): $4,5007,000
• Remote monitoring package (vibration sensors, temperature probes, PLC interface): $8,50012,000
• Mobile skid or trailer mounting: $12,00018,000
• Integrated dust collection fan and ductwork: $15,00025,000
• Custom screen media (nonstandard apertures, special alloys): $2,0005,000 per deck



Service Packages:

• Basic Warranty: 12 months parts and labor (included)
• Extended Warranty: 2436 months, includes annual inspection and priority technical support: $4,5008,000/year
• Preventive Maintenance Program: Quarterly site visits, vibration analysis, wear measurement, media replacement planning: $12,00018,000/year
• Operator Training: 2day onsite training for up to 6 personnel: $3,500 (travel not included)

Financing Options:

• Net 30 terms for qualified buyers (credit check required)
• Leasetoown: 3660 month terms, monthly payments starting at $1,200 (standard package)
• Equipment financing: 515% down, 47% APR (based on credit rating)
• Volume discounts: 5% for 23 units, 10% for 4+ units

Frequently Asked Questions

Q: Can this white label vibration screen handle coke with moisture content above 8%?
A: For dry screening, maximum recommended moisture is 8%. Above this, blinding increases significantly. We offer a wet screening option with spray bars (0.51.5 m³/ton water consumption) that handles up to 15% moisture. Alternatively, a heated deck option (electrical resistance to 60°C) can reduce surface moisture effects for materials up to 10% moisture.

Q: What is the typical delivery lead time for a standard unit?
A: Standard package (WLC1224) ships in 68 weeks from order. Enhanced and premium packages require 1014 weeks due to custom fabrication of dust enclosures and VFD integration. Rush orders (46 weeks) are available at a 15% premium.

Q: How does the white label arrangement work for OEM branding?
A: We supply the complete screen assembly with your company nameplate, paint color (RAL code), and documentation. No manufacturer markings appear on the equipment. Technical drawings and manuals are provided in your brand format. Minimum order: 2 units for custom branding.

Q: What screen media is recommended for metallurgical coke with 57% moisture?
A: Polyurethane modular panels (6070 Shore A hardness) with 4050% open area are optimal. They resist blinding from sticky fines and provide 1418 weeks life. For highabrasion applications (e.g., calcined coke), 92% alumina ceramic tiles on the feed box and polyurethane on the deck offer the best balance of wear life and cost.

Q: Can the screen be integrated with an existing PLC or SCADA system?
A: Yes. The VFD and vibration monitoring package include Modbus RTU (RS485) or Ethernet/IP communication protocols. We provide a standard tag list and integration guide. For custom PLC programming, add $2,5004,000 to the premium package.

Q: What is the expected ROI timeline for a typical installation?
A: Based on field data from 47 installations, average payback is 1014 months. Primary savings come from reduced screen media replacement costs (4060% reduction), lower maintenance labor (120180 hours/year), improved product quality (eliminating rescreening and penalties), and reduced energy consumption (2028%). A detailed ROI calculator is available upon request.

Q: How does the dust enclosure affect access for maintenance?
A: The enclosure uses bolted panels with quickrelease latches on inspection doors. All service points (vibrator bearings, screen media tensioning, motor access) are reachable through dedicated access panels. Full enclosure removal for major maintenance takes 23 hours with two technicians. The enclosure is designed to meet OSHA confined space requirements.