1. PAINPOINT DRIVEN OPENING

Is your foundry or steel plant’s coke screening operation a persistent bottleneck? Inconsistent feed, abrasive material, and demanding production schedules create significant challenges that directly impact your bottom line. Are you experiencing:
Excessive Downtime: Frequent screen cloth changes and structural fatigue from highimpact loading, leading to hours of lost production per month.
Uncontrolled Emissions & Dust: Fugitive coke fines creating environmental compliance headaches, housekeeping issues, and potential health hazards for operators.
Poor Fraction Accuracy: Inconsistent separation of breeze from furnacegrade coke, resulting in product quality issues and inefficient furnace operation.
High Maintenance Costs: Premature failure of nonspecialized components due to abrasion and vibration stress, driving up spare part inventories and labor hours.

What if your screening station could deliver reliable, clean, and efficient performance with significantly reduced operational intervention?

2. PRODUCT OVERVIEW

The Rohs Compliant Coke Vibration Screen is a heavyduty industrial screening machine engineered for the precise dry separation of metallurgical coke. It is designed to handle the abrasive nature and specific size distribution requirements of coke prior to blast furnace charging.

Operational Workflow:
1. Controlled Feed: Coke is delivered via conveyor onto the screen’s robust feed box, which evenly distributes material across the full width of the screening surface.
2. HighEfficiency Separation: A dualvibrator motor drive generates a linear or elliptical vibratory motion, stratifying and conveying material across the screen decks. Precisely sized apertures separate furnace coke (oversize) from coke breeze (undersize).
3. Clean Discharge: Separated fractions are discharged via dedicated chutes—furnacegrade coke to the charge system, fines to collection—minimizing intercontamination.

Application Scope & Limitations:
Scope: Ideal for dry screening of metallurgical coke in steel plants, foundries, and coke production facilities. Effective for size ranges typically from 25mm to 80mm.
Limitations: Not designed for wet screening applications or for materials with high moisture content that causes blinding. Maximum lump size is limited by specific model feed inlet dimensions.

3. CORE FEATURES

RohsCompliant Construction | Technical Basis: Restriction of Hazardous Substances Directive | Operational Benefit: Guarantees all electrical components, wiring, and soldering are free from lead, cadmium, mercury, and other restricted substances. | ROI Impact: Facilitates global export to regulated markets (EU, China), eliminates supply chain risk for noncompliant parts, and supports corporate sustainability mandates.

AbrasionResistant Deck System | Technical Basis: Highcarbon steel or alloy screen cloths with reinforced edge preparation | Operational Benefit: Withstands the extreme abrasion of sharpedged coke particles, extending service life by up to 40% over standard decks. | ROI Impact: Reduces frequency and cost of screen media replacement directly lowering costperton screened.

DustEncapsulated Design | Technical Basis: Sealed dust covers with quickrelease clamps and silicone gasketing at all transfer points | Operational Benefit: Contains up to 95% of fugitive dust at source under negative pressure ventilation. | ROI Impact: Lowers housekeeping costs, reduces exposure risks for cleaner compliance with workplace air quality standards.

Modular Vibrator Assembly | Technical Basis: Externally mounted, synchronized vibrator motors with easyaccess grease lines | Operational Benefit: Enables maintenance or motor replacement without dismantling the main screen body or disrupting feed/discharge chutes. | ROI Impact: Cuts planned maintenance downtime by over 50%, increasing plant availability.

StressRelieved Frame Structure | Technical Basis: Finite Element Analysis (FEA) optimized steel frame with postweld heat treatment | Operational Benefit: Eliminates points of high cyclic stress concentration that lead to crack initiation under continuous operation. | ROI Impact: Provides structural integrity for a longer operational lifespan (>10 years), protecting capital investment.

Tuned Isolation Springs | Technical Basis: Computercalibrated steel coil or rubber isolation mounts matched to dynamic load | Operational Benefit: Absorbs over 85% of dynamic forces preventing transmission to the supporting structure. | ROI Impact: Eliminates costly structural reinforcement requirements on existing platforms and reduces noise pollution.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard Benchmark | Rohs Compliant Coke Vibration Screen Solution | Advantage (% Improvement) |
| : | : | : | : |
| Screen Cloth Lifespan (Abrasive Service) | ~600 Operating Hours | ~850 Operating Hours (with equivalent media) +42% |
| Mean Time Between Failure (Structural)| ~14 Months Continuous Operation| >24 Months Continuous Operation (projected) +71% |
| Contained Dust Emissions at Transfer Points| 95% Contained +19% |
| Vibrator Motor Replacement Time| 68 Hours (requiring partial disassembly)| <2 Hours (modular boltoff) 75% Downtime |
| Dynamic Force Transmitted to Support Structure| ~40% of Dynamic GForce| <15% of Dynamic GForce 63% Load |

5. TECHNICAL SPECIFICATIONS

Model Range Capacity: From 150 TPH to 800 TPH throughput capacity.
Power Requirements: Dual vibrator motors from 2 x 5 kW up to 2 x 22 kW; standard supply voltage is either IECstandard or NEMAstandard as specified.
Material Specifications: Main frame – S355JR structural steel; Screen decks – Hardox® wear plates or equivalent; Screen cloth – Highcarbon steel (65Mn), stainless steel optional; All fasteners – Grade 8.8 or higher with corrosion protection.
Physical Dimensions (Typical Model): Working deck area options from 3m² to 12m²; Overall length varies from ~4m to ~8m depending on deck configuration.
Environmental Operating Range: Ambient temperature range 20°C to +45°C; Designed for IP66 protection on electrical components; Suitable for outdoor installation.

6. APPLICATION SCENARIOS

[Integrated Steel Plant] Challenge: A major mill faced unplanned downtime every six weeks due to cracked side plates on their primary coke screens near the blast furnace bins. Dust emissions also exceeded internal targets.

[Coke Production Facility] Challenge: A producer exporting specialty coke needed equipment certified for international markets while struggling with high maintenance costs from rapid deck wear on their older screens.

[Foundry Operation] Challenge: A foundry expanding its cupola operations had limited space on an existing structure requiring a new screen that would not impose excessive dynamic loads.

[Solution]: Implementation of a customwidth Rohs Compliant Coke Vibration Screen with FEAoptimized side plates. The design included full dust encapsulation tied into the existing baghouse system.

[Solution]: Installation of two parallel Rohs Compliant Coke Vibration Screens featuring abrasionresistant deck systems. Full RoHS documentation was provided for all components.

[Solution]: Installation of a compact Rohs Compliant Coke Vibration Screen fitted with highefficiency tuned isolation springs. The modular vibrators allowed servicing within tight spatial confines.

[Results]: Structural issues were eliminated over an 18month observation period. Dust emissions at the source were reduced by over 90%, achieving compliance targets while increasing annual availability by approximately 400 hours.

[Results]: Deck replacement intervals extended from an average of eight weeks out beyond twelve weeks. The plant secured its export contract with full machinery compliance documentation provided upon delivery.

[Results]: Dynamic forces measured on the support structure were within original design limits. The foundry achieved required throughput without costly platform reinforcement while benefiting from reduced vibration noise levels noted by operators.

7. COMMERCIAL CONSIDERATIONS

Our pricing structure reflects build quality and engineering investment:
Standard Tier: Base model covering core capacity ranges with standard abrasion packages.
HighAvailability Tier: Includes upgraded bearing assemblies premium isolators extended warranty coverage
Optional features include various screen cloth materials polyurethane deck coatings integrated spray bars for limited antiblinding duty automated lubrication systems
We offer comprehensive service packages:
Onsite installation supervision commissioning
Scheduled maintenance contracts
Critical spare parts kits
Financing options including equipment leasing are available through our partners

8.FAQ

1.Q Is this RoHS compliance relevant outside European operations?
A Yes Beyond regulatory requirements RoHS compliance ensures higher reliability electronic components reduces longterm exposure risks associated hazardous substances making it sound operational policy globally

2.Q Can this screen replace our existing unit without modifying feed conveyors discharge hoppers?
A Our engineering team provides dimensional drawings force load data interface review ensure retrofit compatibility Minimal chute modification typically required

3.Q What measurable impact can we expect on our operating costs?
A Field data shows primary savings come extended media life reduced structural maintenance Based historical benchmarks operators report total screening cost reduction between per ton processed

4.Q How does warranty work cover such heavyduty application?
A We offer months structural warranty months mechanical electrical component warranty conditional proper installation adherence recommended maintenance schedules Detailed terms provided quotation

5.Q What lead time should we anticipate after order placement?
A Lead times vary based model specification complexity Current standard range weeks confirmed upon receipt detailed operational parameters

6.Q Are performance guarantees offered?
A Yes We guarantee rated throughput capacity separation efficiency based your provided material size analysis specific guarantee document accompanies commercial proposal

7.Q Do you provide assistance commissioning operator training?
A Yes Factorytrained engineers available supervise installation conduct performance testing provide handson operator maintenance training ensure optimal startup