Headline: Precision Screening for HighValue Coke: Reducing Fines Generation and Maximizing Yield

1. PAINPOINT DRIVEN OPENING

Every ton of sized coke lost to fines or offspec material represents a direct hit to your bottom line. Plant managers in the metallurgical and petroleum coke sectors face a specific set of operational challenges:

• Excessive Fines Generation: Standard vibratory screens often degrade fragile calcined or metallurgical coke, increasing the 6mm fraction by 35% and reducing saleable product value.
• Blinding and Pegging: The irregular, porous surface of coke particles causes rapid screen cloth blinding, leading to a 1520% drop in throughput efficiency within a single shift.
• High Maintenance Costs: Abrasive coke dust accelerates wear on bearings, springs, and side plates, forcing unscheduled downtime every 200300 operating hours.
• Inconsistent Product Quality: Inability to maintain strict particle size distribution (PSD) tolerances results in rejected shipments and contractual penalties.
• Vibration Transmission to Structure: Heavy vibrating decks transmit destructive forces to support steelwork, increasing structural fatigue and safety risks.

Are your current screening assets costing you 23% of total yield per month? Is your maintenance team spending more time replacing screen decks than optimizing production? The solution requires a machine engineered specifically for the lowmoisture, highabrasion, friable nature of coke.

2. PRODUCT OVERVIEW

The Luxury Coke Vibration Screen is a heavyduty, linearmotion vibratory classifier designed for the precise sizing of calcined petroleum coke (CPC), metallurgical coke, and foundry coke. It operates on the principle of highGforce, lowstroke vibration to stratify and separate particles without excessive impact.

Operational Workflow (35 Key Steps):

1. Feed Distribution: Material enters via a flared feed box with a replaceable wear liner, ensuring even distribution across the full width of the deck.
2. Stratification: Highfrequency, lowamplitude vibration (1216 Gforce) causes fine particles to migrate through the bed to the screen surface.
3. Separation: Material passes over a multideck configuration (typically 23 decks) with polyurethane or stainless steel wire mesh. The top deck removes oversize (+50mm), the middle deck produces the target fraction (e.g., 1030mm), and the bottom deck extracts fines (6mm).
4. Dedusting: An integrated, negativepressure plenum beneath the bottom deck captures airborne coke dust, reducing environmental loading and improving operator safety.
5. Discharge: Sized fractions exit through dedicated spouts with abrasionresistant ceramic liners.

Application Scope and Limitations:

• Scope: Dry screening of coke with moisture content below 5%. Ideal for final sizing before storage, blending, or loading.
• Limitations: Not suitable for wet screening or slurries. Maximum feed temperature should not exceed 80°C (176°F) to prevent polyurethane deck warping.

3. CORE FEATURES

HighG Linear Motion Drive | Technical Basis: Twinshaft, counterrotating vibrator motors with synchronized timing gears | Operational Benefit: Generates 1216 Gforce for rapid stratification without the vertical lift that causes particle breakage | ROI Impact: Reduces fines generation by up to 40% compared to circularmotion screens, preserving 1.52% of saleable product value.

Modular Polyurethane Screen Panels | Technical Basis: Injectionmolded, abrasionresistant polyurethane (Shore A 90) with selfcleaning pinhole apertures | Operational Benefit: Eliminates wire cloth breakage and reduces blinding from irregular coke shapes | ROI Impact: Extends screen deck life from 300 hours (wire mesh) to 2,500+ hours, reducing annual replacement costs by 60%.

Isolated Support Structure | Technical Basis: Heavyduty coil springs with integrated rubber buffers and a tuned base frame | Operational Benefit: Reduces dynamic load transmission to building steel by 85% | ROI Impact: Eliminates need for structural reinforcement, saving $15,000$30,000 in civil engineering costs per installation.

Integrated Dust Containment Plenum | Technical Basis: Welded, gasketed enclosure with negativepressure extraction ports | Operational Benefit: Captures 95% of airborne particulate at the source | ROI Impact: Reduces plant ventilation load and meets OSHA PEL standards for respirable coke dust without additional baghouses.

QuickChange Deck System | Technical Basis: Tensioned, sidecompression rails with hydraulic deck lifters | Operational Benefit: Allows a single operator to replace a full deck in under 45 minutes | ROI Impact: Reduces changeover downtime from 4 hours to 45 minutes, recovering 3.5 hours of production per change.

AbrasionResistant Wear Package | Technical Basis: 12mm AR400 steel liners in feed zone and discharge spouts, with ceramic tile inserts at highwear points | Operational Benefit: Withstands 50,000+ tons of coke throughput before liner replacement | ROI Impact: Reduces annual maintenance labor by 120 hours per machine.

Variable Frequency Drive (VFD) Control | Technical Basis: 060 Hz VFD on vibrator motors with closedloop amplitude feedback | Operational Benefit: Allows operators to adjust Gforce in realtime based on feed rate and coke quality | ROI Impact: Optimizes power consumption by 15% and prevents overscreening of friable material.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Circular Motion) | Luxury Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Fines Generation (6mm) | 812% of feed | 46% of feed | 50% reduction |
| Screen Deck Life | 300500 hours (wire) | 2,0002,500 hours (polyurethane) | 400% increase |
| Blinding Frequency | Every 8 hours (requires manual cleaning) | Every 120 hours (selfcleaning) | 1,400% improvement |
| Dynamic Load to Structure | 100% (unbalanced) | 15% (isolated) | 85% reduction |
| Changeover Time (per deck) | 4 hours (2person crew) | 45 minutes (1person crew) | 81% faster |
| Throughput Efficiency | 7580% of rated capacity | 9295% of rated capacity | 1520% increase |

5. TECHNICAL SPECIFICATIONS

| Parameter | Specification (Model LCVS2460) |
| : | : |
| Rated Capacity | 150200 tons per hour (coke, bulk density 0.8 t/m³) |
| Screening Area | 14.4 m² (2 decks x 2.4m width x 6.0m length) |
| Vibration Type | Linear motion, 45° angle |
| GForce Range | 1016 G (adjustable via VFD) |
| Stroke | 610 mm (variable) |
| Vibrator Motors | 2 x 15 kW (20 HP), 1800 RPM, TEFC, IP55 |
| Power Supply | 460V / 3phase / 60 Hz (380V / 50 Hz optional) |
| Screen Media | Polyurethane modular panels, 6mm to 50mm apertures |
| Material of Construction | Frame: Carbon steel (ASTM A36) with epoxy paint; Liners: AR400; Spouts: Ceramic tile |
| Physical Dimensions (L x W x H) | 8.5m x 3.2m x 3.8m (including discharge chutes) |
| Operating Weight | 18,500 kg (with motors and media) |
| Environmental Range | 20°C to +50°C; 095% noncondensing humidity |
| Noise Level | < 85 dBA at 1 meter (with dust enclosure) |

6. APPLICATION SCENARIOS

Calcined Petroleum Coke (CPC) Terminal | Challenge: A Gulf Coast storage terminal was losing 3% of product to fines during final screening before vessel loading. The existing circularmotion screens caused particle attrition, and wire decks blinded after 6 hours of operation. | Solution: Installation of a dualdeck Luxury Coke Vibration Screen with 12mm and 6mm polyurethane panels, VFD control set to 14 Gforce. | Results: Fines generation dropped from 11% to 5.5% of feed. Screen deck life extended to 2,800 hours. Annual recovered product value: $480,000 based on 500,000 tons throughput.

Metallurgical Coke Plant (Blast Furnace Grade) | Challenge: A steel mill required consistent 2540mm coke for blast furnace injection. Inconsistent sizing caused furnace permeability issues and increased coke rate by 5 kg/ton of hot metal. | Solution: A tripledeck Luxury Coke Vibration Screen with top deck at 50mm, middle at 25mm, and bottom at 10mm. | Results: PSD variability reduced from ±8mm to ±3mm. Blast furnace coke rate decreased by 3 kg/ton, saving $1.2M annually in coke purchases. Maintenance downtime reduced from 12 hours/month to 3 hours/month.

Foundry Coke Producer | Challenge: A foundry coke producer needed to eliminate 6mm fines from the final product to meet customer specifications. Manual screening was laborintensive and inconsistent. | Solution: A singledeck Luxury Coke Vibration Screen with 6mm polyurethane panels and integrated dust extraction. | Results: Fines content in final product reduced from 4% to 0.8%. Rejected shipments dropped from 15% to 0%. Payback period on the equipment: 8 months.

7. COMMERCIAL CONSIDERATIONS

Equipment Pricing Tiers (FOB, excluding installation):

• Standard Model (LCVS1848): $85,000 $110,000 (2deck, 100 TPH capacity)
• HighCapacity Model (LCVS2460): $145,000 $185,000 (23 deck, 200 TPH capacity)
• Custom Configuration: $200,000+ (for extreme abrasion packages, stainless steel construction, or explosionproof motors)

Optional Features (Addon Costs):

• ExplosionProof Package: $12,000 (ATEX/IECEx certified motors and electricals)
• Remote Monitoring System: $8,500 (vibration sensors, bearing temperature probes, PLC interface)
• Heated Screen Deck Option: $6,000 (for highmoisture coke, prevents blinding)
• Ceramic Tile FullLiner Package: $15,000 (extends wear life by additional 40%)

Service Packages:

• Basic (Annual): $4,500 (inspection, lubrication, tension check)
• Premium (Quarterly): $12,000 (includes deck rotation, bearing replacement, vibration analysis)
• Full Turnkey (Installation + Commissioning): $25,000 $40,000 (site prep, rigging, electrical, training)

Financing Options:

• LeasetoOwn: 3660 month terms, 4.56.5% APR (subject to credit approval)
• PerformanceBased Financing: Payments tied to throughput or yield improvement targets
• TradeIn Program: 1015% credit on any brand of existing vibrating screen

8. FAQ

Q1: Can the Luxury Coke Vibration Screen handle green (raw) petroleum coke?
A: Yes, but with limitations. Green coke with moisture above 8% will cause some blinding on polyurethane panels. We recommend a heated deck option or a predrying stage for moisture content exceeding 10%. For dry green coke (<5% moisture), performance is equivalent to calcined coke.

Q2: What is the expected lifespan of the vibrator motors under continuous operation?
A: Field data from 47 installations shows a mean time between failures (MTBF) of 18,000 hours for the vibrator motors when operated within the specified Gforce range. Bearing replacement is recommended every 8,000 hours as part of the Premium service package.

Q3: How does this screen compare to a flipflow screen for sticky coke?
A: For dry coke (10%) but have higher maintenance costs due to flexible screen mats. Our solution is optimized for dry, friable coke.

Q4: What is the typical payback period for replacing an existing circularmotion screen?
A: Based on a 200 TPH operation running 6,000 hours per year, the payback period is 1014 months. This is driven by reduced fines loss (1.52% yield improvement), lower maintenance costs (60% reduction), and decreased downtime (81% faster changeovers).

Q5: Can the screen be retrofitted into an existing structure without major civil works?
A: Yes. The isolated support structure reduces dynamic load by 85%, meaning most existing steelwork can handle the static weight without reinforcement. We provide a structural load analysis report for your specific site conditions prior to installation.

Q6: What warranty is provided on the screen deck panels?
A: Polyurethane panels carry a 24month warranty against manufacturing defects and premature wear (based on throughput of 100,000 tons). Wire mesh decks are warranted for 6 months. The main frame and vibrator assembly carry a 36month warranty.

Q7: How does the VFD control improve screening efficiency for varying coke quality?
A: When feed contains a higher percentage of friable material (e.g., from a different source), operators can reduce Gforce from 16 to 12 G via the VFD. This prevents overscreening and particle breakage. Conversely, for harder coke, Gforce can be increased to maintain throughput. Field data shows a 15% reduction in fines generation when using VFD optimization.