1. PAINPOINT DRIVEN OPENING

Are your coke screening operations plagued by persistent, costly inefficiencies? Plant managers and engineering contractors face significant challenges in maintaining consistent product quality and throughput. Common pain points include:
Blinding & Carryover: Moisture and fine particles adhere to screen decks, blinding apertures and forcing material carryover. This results in offspec product, increased recrushing loads, and wasted yield.
Excessive Downtime & Maintenance: Frequent screen cloth changes and structural repairs due to aggressive vibration or material abrasion halt your production line, directly impacting your bottom line.
Inconsistent Sizing & Yield Loss: Ineffective screening leads to missized coke fractions, compromising blast furnace efficiency for your customers and eroding your profit margins.
High Operational Costs: Premature component failure, high energy consumption from inefficient drives, and laborintensive cleaning procedures inflate your costperton.

Is there a screening solution engineered to withstand the abrasive nature of metallurgical coke while delivering precise separation with maximum uptime?

2. PRODUCT OVERVIEW

The ISOCertified Coke Vibration Screen is a heavyduty linear or elliptical motion vibrating screen specifically engineered for the dry separation of metallurgical coke into precise size fractions (e.g., blast furnace coke, nut coke, breeze). Its robust design addresses the unique abrasiveness, density, and size range of coke particles.

Operational Workflow:
1. Feed & Distribution: Sized coke from crushers is evenly distributed across the full width of the screen’s feed box.
2. Stratification & Separation: HighGforce vibration stratifies material; fines pass through the configured screen cloth apertures while oversize travels toward the discharge end.
3. Discharge: Correctly sized fractions are discharged into separate chutes or conveyors for stockpiling or shipment.

Application Scope: Primary and secondary screening of metallurgical coke in coke plants, steel mills, and bulk handling terminals. Ideal for sizing ranges from 80mm down to 05mm breeze.

Limitations: Not designed for wet screening applications or for materials with extreme temperature (>150°C) without specific modifications.

3. CORE FEATURES

HeavyDuty Deck Support System | Technical Basis: Reinforced crossmembers with rubber buffer pads | Operational Benefit: Eliminates direct metaltometal contact, drastically reducing noise (<85dB) and dissipating destructive harmonic vibrations | ROI Impact: Extends screen cloth and structural life by up to 40%, reducing part replacement costs and downtime.

Modular Polyurethane Screen Panels | Technical Basis: Abrasionresistant PU with reinforced steel backing | Operational Benefit: Highly resistant to wear from sharp coke edges; antiblinding properties reduce pegging | ROI Impact: Panel service life is 35x longer than wire mesh, lowering consumable inventory costs and changeout labor.

DualVibration Motor Drive System | Technical Basis: Two synchronized externally mounted motors generating linear motion | Operational Benefit: Simplified maintenance; no complex gearboxes or driveshafts; easy adjustment of amplitude | ROI Impact: Proven motor reliability reduces drive system failures; energyefficient design cuts power consumption per ton screened.

Total Enclosure Dust Containment Skirt | Technical Basis: Multistage rubber sealing system around deck perimeter | Operational Benefit: Effectively contains coke dust at transfer points, improving site safety and environmental compliance | ROI Impact: Minimizes material loss as product dust and reduces housekeeping labor requirements.

QuickRelease Tensioning System for Screen Cloths | Technical Basis: Lateral tensioning rails with simple bolt mechanisms | Operational Benefit: Enables singleoperator screen panel change in under 30 minutes versus industrystandard hours | ROI Impact: Directly increases plant availability by minimizing planned maintenance windows.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Coke Screen) | ISOCertified Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screen Cloth Life | 23 months with wire mesh panels | 812 months with modular PU panels | +300% service life |
| Annual Availability| ~92% (700+ hrs downtime) | >96% (<350 hrs downtime) | +4% absolute availability |
| Sizing Accuracy| ~9092% efficiency (varies with moisture)| >95% consistent efficiency (antiblinding design) | +35% efficiency gain |
| Noise Emission| Often exceeds 90 dB(A) at 1 meter| Maintains <85 dB(A) at 1 meter| Significant reduction in noise exposure |
| Energy Consumption| Baseline per ton processed| Up to 15% lower kWh/ton (optimized drive/mass)| 15% operational cost |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in widths from 1.2m to 3.6m; lengths from 4.8m to 10m. Capacities from 200 to over 1500 metric tons per hour, depending on aperture size and feed gradation.
Power Requirements: Dual vibration motors ranging from 2 x 7.5 kW to 2 x 45 kW (400V/50Hz or as specified). Total installed power depends on machine size and mass.
Material Specifications: Main frame: S355JR structural steel. Deck frames: Hardox® wear plate or equivalent on critical areas. Screen panels: Customizable polyurethane or rubber compounds for required cut point.
Physical Dimensions & Mass: Varies significantly by model. Example (Medium Duty): Width=2.4m, Length=6m; Approximate Mass=8,500 kg excluding motors.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Bearings rated for continuous operation up to +120°C surface temperature.

6. APPLICATION SCENARIOS

[Integrated Steel Plant] Challenge: A major steel producer faced consistent yield loss due to fine coke (<10mm) contaminating blast furnacegrade fraction (+25mm). Manual cleaning of blinded wire mesh screens was required weekly.

[Merchant Coke Producer] Challenge: A merchant plant needed to increase throughput after a crusher upgrade but was bottlenecked by an older screening stage that could not handle the increased load without excessive carryover.

[Solution:] Implementation of a primaryclassifying ISOCertified Coke Vibration Screen fitted with multislope PU panels on the top deck.

[Results:] Sizing accuracy improved from ~88% to over 96%. Blindingrelated stoppages were eliminated.

[Solution:] Installation of two widebody linear motion screens in parallel for load distribution.

[Results:] Screening capacity matched crusher output at over 800 tph per line.

7. COMMERCIAL CONSIDERATIONS

Our ISOCertified Coke Vibration Screens are offered in three primary tiers:

Standard Duty Tier: For lowercapacity lines (<400 tph), featuring robust construction with standard wear liners.
HeavyDuty Tier (Most Common): Includes all core features listed above (PU panels, quickrelease systems), designed for mainline primary/secondary screening.
Premium Tier: Includes full instrumentation (vibration monitoring sensors), automated lubrication systems, and special coatings for highly corrosive environments.

Optional features include stainless steel components for specific zones, custom feed boxes/hoppers, spray bar systems for controlled dust suppression during transfer.

We offer comprehensive service packages ranging from annual inspections with condition reports to full longterm maintenance agreements including parts supply.

Flexible financing options are available through our partners including equipment leasing programs tailored for capital expenditure cycles common in mineral processing industries.

8.FAQ

Q1 – Are these screens compatible with our existing feed conveyor discharge heights?
A1 – Our engineering team designs each unit based on your specific layout data provided during quotation including feed height clearances ensuring seamless integration into your current flow sheet without major structural modifications required onsite

Q2 – What is the expected operational impact during installation?
A2 – We provide detailed installation plans requiring typically a fivetosevenday shutdown window depending on foundation preparation requirements performed beforehand by your team

Q3 – How does this solution handle variations in feed moisture content?
A3 – The combination of high Gforce vibration antiblinding panel technology allows effective stratification even with moderate surface moisture Field data shows consistent performance upto four percent surface moisture beyond which predrying is recommended

Q4 – What are typical commercial terms lead time payment structure?
A4 – Standard lead times range between twelvesixteen weeks exworks Payment terms are generally structured as thirty percent upon order sixtyfive percent before shipment five percent after commissioning

Q5 – Do you provide performance guarantees?
A5 – Yes we guarantee mechanical performance against agreed specifications including capacity sizing accuracy under defined feed conditions These are detailed within our commercial proposal

Q6 – Who handles installation supervision commissioning?
A6 – We offer optional expert site supervision commissioning services as part of our technical package ensuring optimal startup performance knowledge transfer directly onto your operating maintenance teams

Q7 – Can we retrofit certain features like quickrelease tensioning onto our existing screens?
A7 – In many cases yes Our service division conducts audits provides retrofit kits modernize older equipment extending its life improving maintainability often providing strong returnoninvestment versus complete replacement