1. PAINPOINT DRIVEN OPENING

Is your coke handling operation struggling with inconsistent product quality, excessive fines generation, and unplanned maintenance costs? Inefficient screening directly impacts your bottom line through lost product, increased energy consumption for downstream processes, and costly production stoppages. Are you facing these challenges?
Blinding & Carryover: Moisture or sticky fines blinding screen meshes, forcing material to carry over unscreened and contaminating your sized product.
Excessive Downtime: Frequent screen cloth changes and structural fatigue from highimpact loads lead to significant operational interruptions.
High Maintenance Costs: Premature failure of vibratory motors, springs, and deck structures due to the abrasive nature of hot coke.
Inefficient Sizing: Inconsistent separation results in offspec product, reducing market value and causing reprocessing expenses.
Dust & Emission Control: Open screening points creating fugitive dust, complicating environmental compliance and housekeeping.

The right industrial screening solution must address these specific, harsh conditions. How can you achieve higher throughput of consistently sized coke while reducing total cost of ownership?

2. PRODUCT OVERVIEW

The Professional Coke Vibration Screen is a heavyduty, highcapacity screening machine engineered for the dry separation of metallurgical coke and petroleum coke. It is designed to handle hot, abrasive materials at high tonnage rates with maximum reliability.

Operational Workflow:
1. Feed & Distribution: Sized coke feed is uniformly distributed across the full width of the screen’s inlet via a robust feed box.
2. Stratified Vibration: A highGforce linear or elliptical motion stratifies the material bed, forcing fines downward to the screen surface while moving oversize material across the deck.
3. Precise Separation: Material is separated into defined fractions (e.g., blast furnace coke, nut coke, breeze) via tailored screen panel configurations.
4. Discharge: Correctly sized fractions discharge from designated outlets into separate chutes or conveyors for further processing or shipment.

Application Scope: Primary and secondary screening of metallurgical coke (blast furnace foundry), petroleum delayed coke, and other similar carbon materials. Ideal for integrated steel plants, coke plants, and carbon anode production facilities.

Limitations: Not designed for wet screening applications or for materials with extreme stickiness without specialized deck treatments. Maximum feed temperature is typically +150°C with standard seals; higher temperatures require specific configurations.

3. CORE FEATURES

HeavyDuty Deck Structure | Technical Basis: Bolted modular construction with reinforced crossmembers | Operational Benefit: Withstands impact loading from large coke pieces without deflection or fatigue cracking | ROI Impact: Extends structural life by up to 40%, reducing capital replacement cycles

AntiBlinding System | Technical Basis: Multipledeck configuration with ball tray decks or flexible screen mats | Operational Benefit: Continuous elastic collisions dislodge lodged particles that cause blinding | ROI Impact: Maintains screening efficiency above 95%, preventing loss of valuable product to incorrect fractions

Dual CounterRotating Exciter Drive | Technical Basis: Two synchronized vibratory motors generating a linear force vector | Operational Benefit: Provides consistent, adjustable Gforce for optimal material travel and stratification | ROI Impact: Delivers up to 25% higher throughput per deck area compared to unbalanced elliptical designs

Hot Material Sealing & Dust Enclosure | Technical Basis: Multilayered labyrinth seals and fulllength dust skirts | Operational Benefit: Contains dust at transfer points and protects bearings from extreme heat and fines ingress | ROI Impact: Reduces airborne particulate matter for compliance and extends bearing service life by over 30%

QuickChange Screen Panel System | Technical Basis: Modular polyurethane or rubberclad steel panels with tensioning hooks | Operational Benefit: Allows single operators to replace panel sections in under 30 minutes without specialized tools | ROI Impact: Cuts maintenance downtime by approximately 70% per changeout event

Finite Element Analysis (FEA) Optimized Side Plates | Technical Basis: Computermodeled stress distribution under dynamic load | Operational Benefit: Eliminates stress concentration points that lead to metal fatigue failures | ROI Impact: Virtually eliminates catastrophic side plate failure, a major source of unplanned downtime

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Typical Screen) | Professional Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screening Efficiency (dry coke) | 8590% sustained efficiency before blinding effects set in. Field data shows an average efficiency above 95% throughout a campaign due to antiblinding systems.| +510% sustained efficiency |
| Screen Cloth/Deck Life (abrasive service) Standard wire mesh panels last ~45 days under continuous operation.| Specialized polyurethane/ rubber composite panels demonstrate service life of ~120 days in comparable duty.| +167% service life |
| Mean Time Between Failure (MTBF) Drive System Unbalanced exciters require bearing service every ~4,000 hours.| Sealedforlife bearings in dual exciter drives have a documented MTBF exceeding 12,000 hours.| +200% MTBF |
| Throughput per Square Meter of Deck Area Typical linear screens handle ~5060 TPH/m² for coke sizing.| Optimized throw angle & Gforce enable rates of 7080 TPH/m² without loss of accuracy.| +25% capacity density |

5. TECHNICAL SPECIFICATIONS

Capacity Range: Models available from 100 to 1,500+ metric tons per hour (TPH), depending on aperture size and fraction count.
Screen Decks: Single, double, or tripledeck configurations based on separation requirements.
Drive Power: Electromechanical exciter drives ranging from 2 x 7.5 kW to 2 x 45 kW per unit.
Deck Construction: Heavyduty hotrolled steel frame with boltedin crossmembers; optional stainlesssteel contact areas for corrosion resistance.
Screen Media Options: Hightensile woven wire mesh; tensioned polyurethane panels; rubberclad perforated plate; flipflow mats for extreme stickiness.
Physical Dimensions (Typical DoubleDeck): Length: ~6m 8m; Width: ~2m 3m; Height (varies by incline): ~2m 3m.
Operating Environment: Designed for ambient temperatures from 20°C to +50°C; handles material temperatures up to +150°C standard (+250°C with hightemp seals).
Vibration Isolation: Multilayer rubber shear mounts or coil spring isolators standard.

6. APPLICATION SCENARIOS

Integrated Steel Plant – Blast Furnace Feedstock

Challenge: A major steel producer experienced frequent blinding on their primary coke screens during humid conditions. This caused oversized material (>80mm) to contaminate the blast furnace nut coke fraction (2580mm), disrupting burden permeability and increasing fuel rate.
Solution: Implementation of a tripledeck Professional Coke Vibration Screen equipped with ball tray decks on the top two decks for antiblinding action.
Results: Screening efficiency stabilized at >96%. Oversize contamination in the nut coke fraction fell below <1%. The plant reported an estimated annual savings of $180k in reduced fuel consumption and eliminated manual rescreening labor.

Petroleum Coke Calcining Plant – Product Classification

Challenge: A calciner needed precise classification of calcined petroleum coke into multiple anodegrade fractions (4mm,+2mm,2mm,+1mm). Their existing screens generated excessive fines (1mm) due to aggressive vibration degrading fragile coke edges.
Solution: Installation of two doubledeck screens featuring adjustable lowGforce linear motion and gentledecline decks fitted with wearresistant polyurethane screens.
Results: Fines generation was reduced by approximately 15%, reclaiming valuable product yield. Precise cut points improved anode quality consistency. The gentle action also reduced dust generation at the source by an estimated 40%.

7. COMMERCIAL CONSIDERATIONS

Our supply chain provides solutions scaled to operational needs:
Standard Series (Tier I): Preengineered models for common capacities (<500 TPH). Offers proven reliability at competitive capital cost with shorter lead times.
Custom Engineered Series (Tier II): Tailored solutions for hightonnage (>500 TPH), extreme temperature applications (>150°C), or complex multifraction layouts requiring specific deck arrangements.

Optional features include:
Stainless steel internal liners
Advanced condition monitoring sensors
Explosionproof motor specifications
Customized discharge hoods & chutework
Automated lubrication systems

Service packages are available postinstallation:
12/24month comprehensive warranty
5year structural integrity guarantee
24/7 remote technical support access
Annual inspection & vibration analysis programs

Financing options include capital purchase through our partners as well as leasetoown agreements designed over typical equipment lifespans.

FAQ

What is the typical installation footprint required?

Installation requires a prepared concrete foundation capable of supporting dynamic loads plus adequate clearance above for screen media changes (~1 meter minimum). Our engineering package includes detailed foundation drawings specific to your model.

How does this equipment integrate with our existing conveyor system?

The feed height and discharge heights are engineered based on your provided layout drawings during quotation phase . Standard inlet flanges match common chute designs , ensuring mechanical compatibility .

What are the primary operational costs beyond initial purchase?

Operational costs are dominated by energy consumption , periodic replacement of wear parts like screen panels , isolation elements ,and planned bearing service . Our design minimizes all three through efficient drive systems , longlife components ,and extended service intervals .

Can you supply compatible spare parts if we use a different brand's crusher or conveyor?

Yes . As a dedicated equipment supplier , we maintain an extensive inventory industrystandard bearings , motors , seal kits ,and customfabricated wear parts like side plates . We ensure compatibility through technical drawings .

What data supports your claimed improvements in screening efficiency ?

Improvements are based on beforeandafter material analysis reports conducted at client sites . These reports measure particle size distribution before entering our screen versus after each separated fraction . We provide anonymized case summaries upon request .

Do you offer site supervision during installation ?

Yes . We strongly recommend our commissioning supervision package which includes one technician onsite during erection alignment static testing dynamic startup final performance verification This ensures optimal performance from day one .

What is your lead time from order placement ?

Lead time depends on model complexity For Tier I Standard Series expect delivery within weeks For Tier II Custom Engineered Series typical manufacturing time ranges months following final design approval