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Is Inconsistent Coke Sizing Costing You $50,000+ Per Shift in Rejects and Downtime?

In the metallurgical and petroleum coke processing industry, a single screen deck failure or a 2% deviation in particle size distribution can halt a calciner or disrupt a downstream anode plant. You face the daily challenges of:

• Blinding and Peening: Collant, highmoisture coke fines clogging standard screens, reducing effective open area by up to 40%.
• Fatigue structurelle: Constant highGforce vibration cracking welds on nonreinforced frames, leading to unplanned 12hour maintenance shutdowns.
• Inconsistent Cut Points: Inefficient stratification causing oversize material to contaminate fines, forcing recrushing cycles that waste energy and wear out crushers.
• Risques de conformité en matière de sécurité: Operating without proper CE certification exposes your plant to regulatory fines and liability for worker safety.

Can your current screening equipment handle the abrasive, highimpact nature of green and calcined coke while maintaining a precise 6mm to 50mm separation? If not, your profit margin is being screened out.

Présentation du produit: The CE Marked Coke Vibration Screen Distributor

This is a heavyduty, linearmotion vibratory screener specifically engineered for the classification and distribution of petroleum coke, coke métallurgique, et coke de fonderie. It is designed to handle hightonnage feed streams (jusqu'à 500 TPH) while providing a precise, multideck separation.

Flux de travail opérationnel:
1. Entrée de flux: Raw coke enters the distributor via a chute, landing on a wearresistant feed box to disperse the material evenly across the full screen width.
2. Stratification: Highamplitude, lowfrequency vibration (700900 RPM) causes heavier, larger particles to rise to the top layer, while fines migrate to the bottom deck.
3. Classification: Material passes through a series of polyurethane or heavyduty woven wire mesh decks (typiquement 24 ponts) pour un dimensionnement précis (par ex., +50mm, 2550mm, 1025mm, 10mm).
4. Distribution: Sized fractions are discharged through dedicated spouts, directly feeding downstream conveyors, storage bins, or calcining kilns.
5. Oversize Reject: Matériau surdimensionné (+50mm) is directed to a crusher circuit or reject chute.

Champ d'application: Ideal for green coke handling at refineries, calcined coke processing at anode plants, and blast furnace coke sizing at steel mills.
Limites: Non recommandé pour les sols mouillés, sticky materials with >15% surface moisture without the addition of a heated deck or ball tray cleaning system.

Fonctionnalités principales

Ensemble d'excitateur robuste | Base technique: Dualshaft, counterrotating gearbox | Avantage opérationnel: Generates a linear stroke of 1014mm, ensuring deep bed stratification without vertical lift | Impact sur le retour sur investissement: Reduces power consumption by 15% compared to circular motion screens, lowering annual energy costs by $8,000$12,000

CE Certified Structural Integrity | Base technique: Analyse par éléments finis (FEA) designed side plates with 10mm thick Strenx 700 acier | Avantage opérationnel: Eliminates frame cracking under continuous 24/7 opération | Impact sur le retour sur investissement: Extends equipment lifespan to 15+ années, reducing capital replacement costs by 30%

Panneaux d'écran modulaires en polyuréthane | Base technique: Slotopening, abrasionresistant polyurethane (Rive A 90) | Avantage opérationnel: Reduces blinding from coke fines; panels are interchangeable in 15 minutes | Impact sur le retour sur investissement: Increases screen deck life by 3x over woven wire, économie $4,500 annually in mesh replacement and labor

Integrated Feed Distributor Box | Base technique: Angled, replaceable AR400 steel liners | Avantage opérationnel: Prevents material segregation at the feed point, ensuring even load distribution | Impact sur le retour sur investissement: Améliore l’efficacité du dépistage en 812%, reducing recirculating loads and energy waste

Système de lubrification automatique | Base technique: Centralized grease manifold with programmable timer | Avantage opérationnel: Assure une lubrification constante des roulements sans intervention de l'opérateur | Impact sur le retour sur investissement: Extends bearing life by 2x, preventing catastrophic failures that cost $15,000+ in repairs and lost production

Vibration Isolation Base Frame | Base technique: Steel coil springs with 95% isolation efficiency | Avantage opérationnel: Transmits less than 5 kN of dynamic force to the support structure | Impact sur le retour sur investissement: Eliminates the need for expensive reinforced concrete foundations, économie $20,000 in civil works per installation

Avantages compétitifs



| Mesure de performances | Norme de l'industrie (Standard Screen) | CE Marked Coke Vibration Screen Distributor | Avantage (% amélioration) |
| : | : | : | : |
| Efficacité du dépistage (6mm cut) | 7580% | 9295% | +1520% |
| Deck Life (Polyuréthane) | 69 mois | 1824 mois | +100150% |
| Structural Frame Warranty | 1 année | 5 années (with FEA certification) | +400% |
| Niveau de bruit à 1 m | 95 dB(UN) | 82 dB(UN) | 14% (safer for operators) |
| Temps de changement (Pont) | 4 heures (2man crew) | 45 minutes (1man crew) | 81% |
| Consommation d'énergie (per ton) | 0.8 kWh/tonne | 0.55 kWh/tonne | 31% |

Spécifications techniques

| Paramètre | Spécification |
| : | : |
| Modèle | CVD2448 (2.4mx 4,8 m) |
| Capacité | 250 500 TPH (depending on cut point) |
| Number of Decks | 2, 3, ou 4 (configurable) |
| Zone d'écran | 11.5 m² par terrasse |
| Vibration Type | Linear Motion |
| Accident vasculaire cérébral | 10 14 mm (réglable) |
| Fréquence des vibrations | 750 900 RPM |
| Puissance du moteur | 2 x 15 kW (TEFC, IP55) |
| Material of Construction | Strenx 700 plaques latérales, AR400 feed box |
| Média d'écran | Polyuréthane (slot or square opening) |
| Operating Temperature | 20°C to +80°C (ambiant) |
| Poids (env.) | 12,500 kilos |
| Dimensions (L x l x H) | 6.2m x 3.0m x 2.8m |
| CE Certification | Oui (DANS 12100, DANS 602041) |

Scénarios d'application

Green Coke Dewatering & Sizing at a Refinery

Défi: A Gulf Coast refinery was experiencing 30% downtime on their coke drum dewatering screens due to blinding from 8% teneur en humidité. Oversize material was damaging downstream crushers.
Solution: Installed a 3deck CE Marked Coke Vibration Screen Distributor with slotted polyurethane panels and a 12mm stroke.
Résultats: Screening efficiency increased to 94%. Crusher wear life doubled. Unplanned downtime dropped from 120 hours/year to 12 heures/an, économie $180,000 en production perdue.

Calcined Coke Classification for Anode Production

Défi: An aluminum smelter needed a precise 0.5mm to 6mm fraction for anode paste. Their existing screens produced high variability (+/ 1.5mm), causing anode quality issues.
Solution: Deployed a 4deck unit with a dedicated feed distributor to ensure even material spread.
Résultats: Particle size distribution tightened to +/ 0.3mm. Anode rejection rate fell from 4% à 0.5%. The ROI was achieved in 11 months due to reduced scrap and rework costs.

Blast Furnace Coke Screening at a Steel Mill

Défi: A steel mill required a consistent +25mm fraction for their blast furnace. Their existing screens were structurally failing after 3 years due to high Gforces.
Solution: Replaced with a CEcertified unit featuring a heavyduty FEAdesigned frame and 5year structural warranty.
Résultats: Structural integrity issues eliminated. The +25mm fraction consistency improved to 98%. The plant achieved a 15% reduction in coke rate (kg coke per ton of iron) due to better burden permeability.

Considérations commerciales

Niveaux de tarification des équipements (GOUSSET, ExWorks):

• Modèle de base (2pont, manual lube): $85,000 $110,000
• Modèle standard (3pont, auto lube, poly panels): $135,000 $175,000
• Modèle haut de gamme (4pont, auto lube, terrasses chauffées, surveillance à distance): $195,000 $250,000

Fonctionnalités facultatives:

• Heated Screen Decks: +$18,000 (for highmoisture applications)
• Ball Tray Cleaning System: +$9,500 (for fine mesh, <3mm)
• Remote Vibration Monitoring System: +$12,000 (maintenance prédictive)
• Custom Chute Work & Support Steel: +$15,000 $30,000

Forfaits de services:

• Garantie standard: 2 years on mechanical components, 5 years on structural frame.
• Plan de service étendu (ESP): $8,500/année (comprend 2 annual inspections, priority parts delivery, 24hour phone support).
• Full Turnkey Installation: $25,000 $45,000 (including commissioning and operator training).

Options de financement:

• Filet 30/60 termes pour les acheteurs qualifiés.
• Leasetoown options starting at $2,800/month for the Standard Model.
• Performancebased payment: 10% upfront, 90% upon achieving 90%+ screening efficiency guarantee.

FAQ

1. What is the maximum moisture content this screen can handle for green coke?
The standard unit handles up to 12% surface moisture. For moisture levels between 12% et 18%, we recommend the optional heated deck system to prevent blinding. Au-dessus de 18%, a thermal drying step is advised before screening.

2. How does the CE certification impact my plant’s safety compliance?
The CE mark certifies compliance with the EU Machinery Directive (2006/42/CE). This includes a full risk assessment, safety circuit design, et documentation. For plants in regulated jurisdictions, this reduces liability and simplifies safety audits.

3. Can this screen be retrofitted into my existing support structure?
Oui. The vibration isolation base frame transmits less than 5 kN of dynamic force. Most existing steel structures rated for 10 kN can support this unit without reinforcement. We provide a free structural load analysis with a purchase order.

4. What is the typical lead time for a custom configuration?
Standard models ship in 810 semaines. Custom configurations (par ex., specific deck angles, special materials) require 1216 semaines. We offer expedited production for an additional 15% fee, reducing lead time to 6 semaines.

5. How do I change the cut point for a different product specification?
Cut points are changed by swapping the polyurethane screen panels. A 2man crew can change a full deck in under 45 minutes. We stock over 50 standard opening sizes (0.5mm to 100mm) for immediate shipment.

6. What is the expected annual maintenance cost?
Annual maintenance costs average $4,000 $6,000. This includes bearing grease (every 40 heures), polyurethane panel replacement (every 1824 mois), and exciter gearbox oil changes (every 2,000 heures). The automatic lubrication system reduces labor costs by 60%.

7. Fournissez-vous des garanties de performance?
Oui. We guarantee a minimum screening efficiency of 90% for your specified cut point (based on a representative material sample). If the unit fails to meet this benchmark after commissioning, we will adjust the stroke, angle, or deck configuration at no cost.