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The Importance and Optimization of Pulse Jet Pressure in Cartridge Dust Collectors

Cartridge dust collectors use cartridges as filtering elements and employ pulse jet technology. They offer significant advantages, such as small size, high efficiency, low investment, and easy maintenance. As a result, they have become an important choice in the industrial dust collection field. In recent years, new technologies and materials have improved the structure and filter media of cartridge dust collectors, leading to widespread applications in industries like cement, steel, power, food, metallurgy, and chemicals.

Structural Optimization and Wide Application

The overall capacity of cartridge dust collectors has increased several times, now exceeding 2000 square meters of filtration area (according to GB6719-86 standards). Compared to traditional dust collectors, they collect fine dust more effectively. They address issues such as high filtration velocity, poor cleaning efficiency, easy wear and tear of filter bags, and high operational costs. Compared to various bag and electrostatic dust collectors on the market, cartridge dust collectors provide larger effective filtration areas, lower pressure differentials, reduced emissions, smaller sizes, and longer service lives. This makes them a new direction in industrial dust collector development.

 

Cartridge dust collectors in a pharmaceutical facility, showcasing their design for efficient dust removal and environmental protection.

Importance of Pulse Jet Pressure

The pulse jet pressure in cartridge dust collectors refers to the high-pressure air injected into the cartridge through an electromagnetic pulse valve. This parameter is crucial for the normal operation of the dust collector, directly affecting dust removal efficiency and service life. Both excessively high and low pulse jet pressures can lead to cartridge blockage or damage, impacting dust collection effectiveness.

 

Normal Range for Pulse Jet Pressure

Typically, the pulse jet air pressure for cartridge dust collectors should remain between 5 to 7 kg/cm². This pressure range ensures effective cleaning of the cartridges while preventing excessive impact.

 

Factors Affecting Pulse Jet Pressure

Several factors influence pulse jet pressure, including air source pressure, cartridge material, filtration area, and operating environment. For example, the stability of the air source pressure directly affects fluctuations in pulse jet pressure, while the quality of the cartridge material affects its response to the pulse backflow.

 

Steps to Adjust Pulse Jet Pressure

To ensure optimal performance of the cartridge dust collector, follow these steps to adjust the pulse jet pressure:

  1. Start the main power of the cartridge dust collector and adjust the cleaning controller.
  2. Listen for sounds and observe the nozzle to check if the electromagnetic pulse valve operates correctly.
  3. Check the pulse jet pressure gauge to ensure its reading falls within the normal range.

 

Maintenance of Pulse Jet Pressure System

Regularly checking and maintaining the pulse jet pressure system is vital for keeping the cartridge dust collector performing at its best. Here are some maintenance tips:

  • Regularly check the air source pressure gauge to ensure it remains stable within the set range.
  • Clean or replace the electromagnetic pulse valve to prevent blockages or damage.
  • Regularly inspect the wear condition of the cartridges and replace them as necessary.

 

Conclusion

As industrial demand continues to grow, cartridge dust collectors are becoming the preferred equipment for dust collection in various industries due to their efficiency, energy savings, and ease of maintenance. By properly adjusting and maintaining the pulse jet pressure, you can maximize the performance of the dust collector and ensure a clean and safe production environment. If you have any questions about cartridge dust collectors or need professional advice, please feel free to contact us. We are here to help!

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Common Issues and Solutions for Bucket Elevators

Bucket elevators are continuous conveying machines that use a series of buckets attached to a non-ending traction element to vertically lift materials. It transports bulk materials in a vertical or near-vertical direction. During normal operation, bucket elevators may encounter various issues. This is normal, just like how people sometimes feel unwell. With proper maintenance, you can effectively manage these problems. However, improper maintenance can lead to significant damage. Below, we will discuss common problems with bucket elevators and their solutions.

The two pictures show different application scenarios of bucket elevators, highlighting the importance of transportation.

1. Unusual Noises During Bucket Elevator Operation

  • Collision Sounds: If the base plate collides with the bucket, adjust the base's tensioning device to ensure the chain is properly tightened.
  • Drive Shaft Issues: If the driven shaft key is loose or the sprocket is misaligned, it can cause the bucket to collide with the housing. Adjust the sprocket position and tighten the key.
  • Guide Plate Collision: If the guide plate collides with the bucket, adjust the position of the guide plate.
  • Material Jam: If material gets trapped between the guide plate and the bucket, increase the material input angle at the base.
  • Bearing Failures: If a bearing fails and cannot operate smoothly, replace it immediately.
  • Foreign Objects: If material blocks or other debris get stuck in the housing, stop the machine and clear the blockage.
  • Sprocket Profile Issues: If the sprocket teeth are misaligned, repair or replace the sprocket.
  • Chain Adjustment: If the drive chain slips, adjust the chain length.
  • Incorrect Housing Installation: If the housing isn’t installed properly, adjust its vertical alignment.

2. Vibration of the Motor Base

  • Motor Malfunctions: Check the motor rotor to ensure it has proper static balance.
  • Installation Accuracy: If you find poor accuracy in the reducer and motor installation, adjust them accordingly.
  • Base Leveling: If the motor base isn’t level, readjust it to meet specifications.
  • Sprocket Installation Errors: If the drive sprocket is incorrectly installed, reinstall it.
  • Sprocket Profile Correction: If the sprocket profile is poor, correct its shape.
  • Sprocket Tightness: If the drive sprocket's tightness is inappropriate, adjust it again.

3. Dust Leakage

  • Damaged Seals: If the flange seal on the housing is damaged, replace it with a new seal, apply sealant, and retighten the flange bolts.
  • Material Leakage: If material leaks from gaps in the head or housing, add seals or apply sealant.
  • Excessive Drop Height: If the drop height of the material is too great, change the feeding method and add a buffering device.

4. Insufficient Lifting Capacity

  • Material Adhesion: If material sticks to the buckets or chutes, clean them regularly.
  • Insufficient Capacity: If the front equipment doesn’t have enough capacity, increase its production capability.
  • Slow Lifting Speed: If the lifting speed is slow, adjust the sprocket speed ratio.
  • Measurement Issues: If the measurement method is incorrect, check the measuring device and verify the material density, then correct the calculation method.

5. Insufficient Material Discharge

  • Insufficient Rear Capacity: If the rear equipment lacks capacity, enhance its production capability.
  • Discharge Chute Issues: If the discharge chute is too small or at an incorrect angle, correct its angle.
  • Adhesive Material Cleanup: Regularly clean the adhesive material from the chute and buckets.

By summarizing these common issues and their solutions, we hope to help you maintain your bucket elevators effectively and ensure its normal operation. If you have any other questions, feel free to consult us!

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Improving Star Discharge Valve Lifespan

The star discharge valve, also known as the rotary discharge valve, is widely used in industries such as chemicals, coal, metallurgy, and food processing. It is usually installed at the inlet or outlet of other equipment, such as the outlet of bag filters and the inlet of pneumatic conveying systems. The main function of this valve is to ensure that powdered materials flow from the upper end to the lower end under gravity. It also isolates the gas systems above and below, preventing interference.

Structure and Principle of the Star Discharge Valve

The star discharge valve is a key device in the transportation of powdered or fine particulate materials. It acts as a transitional device that effectively isolates the gas phases of two systems. Typically, the star discharge valve is installed vertically, with the valve shaft positioned horizontally, allowing gravity to continuously transport materials from the top to the bottom.

 

This valve consists of a housing, an impeller rotor, shaft seals, bearings, and a drive motor. During operation, fine powders or particles fall into the impeller slots under gravity. The rotating impeller then sends the materials to the lower collection hopper or pneumatic conveying system. Throughout this process, the impeller maintains gas isolation between the upper and lower sections by fitting closely with the inner wall of the housing.

 

Structural principle design diagram of star type discharge valve

Analysis of Axial Leakage Causes

Common faults during the operation of the star discharge valve include seal failure, bearing wear, and impeller jamming. Among these, axial leakage is the root cause of these issues. Seal failure typically arises from axial leakage of materials, which in turn leads to bearing wear and impeller jamming.

 

Causes of Seal Failure

A newly installed star discharge valve usually does not show axial leakage in the early stages of use. However, as usage time increases, leakage gradually worsens. When inspecting the sealing surface of the impeller shaft, noticeable wear marks can be observed. Statistical analysis indicates that the strength and hardness of powder particles significantly affect the valve's lifespan. High-hardness catalytic cracking catalyst powders can easily wear down the sealing surfaces during continuous friction, leading to leakage.

 

Structural Improvement Solutions

To address the leakage issue of the star discharge valve, the following effective improvement measures can be implemented:

1. Improve the Wear Resistance of the Impeller Rotor Shaft

Enhancing the wear resistance of the impeller rotor shaft surface is essential for extending the equipment's lifespan. Increasing the surface hardness of the shaft, ensuring it exceeds the hardness of the powder material, can effectively reduce wear. This can be achieved by:

 

  • Using high-strength alloy steel materials, such as 2Cr13 or 3Cr13, and applying heat treatment.
  • Implementing surface treatments like chrome plating, hard alloy spraying, or laser cladding.

2. Improve the Structure of the Impeller Rotor Shaft

Designing the impeller rotor shaft as a split structure can reduce maintenance costs and time. Using threaded connections allows for quick replacement of the shaft heads when seals fail, minimizing the risk of replacing the entire unit. Ensuring that the thread direction matches the motor's rotation can also prevent failures due to jamming.

 

After these structural improvements, the star discharge valve has operated for over a year without any axial leakage, significantly extending its lifespan.

 

Schematic diagram of the impeller rotor shaft structure before and after improvement

Conclusion

Through in-depth analysis of the faults in the star discharge valve, we identified the root causes of axial material leakage and developed effective improvement measures. These not only extend the equipment's lifespan but also reduce maintenance costs. The key measures are:

 

1.Increase the hardness of the sealing surfaces to enhance wear resistance, significantly extending the equipment's lifespan.

2.Use a split structure for the sealing shafts to lower maintenance costs and reduce repair time.


With these improvements, the performance of the star discharge valve has significantly enhanced, providing more reliable solutions for material transport in relevant industries. For more information about our products or services, please contact us. We look forward to providing you with quality solutions!

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Revolutionizing Cement Transfer: The Air Chain Conveyor Solution

Introduction

Company S operates six Φ18×35 cement silos. As shown in the diagram, there are air transport chutes under silos 1, 2, 3, and 4, 5, 6 to convey materials to the outside elevator. In August 2020, the company planned to increase its cement varieties. This required transferring cement from silo 4 to the chute under silos 1, 2, and 3. Due to the high transfer volume (300 m³/h) and the small height difference between the feed and discharge points, installing an air transport chute was not feasible. Other equipment options were either energy-intensive, prone to wear, or incompatible, making the selection and design process difficult.At this point, the storage and transportation department learned about Darko's air chain conveyor. They contacted Darko's technical team. After a site survey and extensive discussions, they finalized the technical plan to use the air chain conveyor. The order was placed at the end of 2020. Due to tight production schedules, installation only started in July 2021 and was completed within the month. The system performed exceptionally well and met all expectations. Here are the key technical features of the project:

Air Chain Conveyor Drawing

1. Guaranteed Process Height

The air chain conveyor can transport materials horizontally. The design moves material from silo 4 to the chute under silo 2. This setup involves an approximately 135° bend. To save on height, we implemented two measures:

 

First, we changed the feed method at the inlet of the first air chain conveyor from the usual top feed to a side feed. This adjustment allows the material to drop directly from the silo's discharge valve to the side of the equipment, saving about 500 mm of space.

 

Second, at the junction of the two air chain conveyors, we switched from the typical vertical overlap to a horizontal overlap. The discharge from the first conveyor feeds into the side of the second conveyor. Due to the 135° angle, this horizontal overlap created a triangular area where material could accumulate, potentially hindering transport. To prevent material buildup, we installed an air cushion at the junction, supplied by a common Roots blower. This significantly reduced resistance, ensuring smooth material flow. As a result, this design saved about 1000 mm in process height, allowing material from silo 4 to enter the chute under silo 2 smoothly.

 

2. Rational Equipment Selection

For a transfer volume of 300 m³/h, a simple layout with a single device and minimal angles could typically use the FUK630 model. However, given the current process requirements, particularly the 135° junction and end discharge, we opted for the FUK800. After several months of operation, we found that this model met the 300 m³/h requirement and handled sudden increases in pressure within the silo without causing blockages.

 

Air chain conveyor real shooting scene

3. Low Energy Consumption

The specifications for the two air chain conveyors are as follows: the first is FUK800×13.5 meters with a power of 5.5 kW, and the second is FUK800×31.7 meters with a power of 11 kW. Both conveyors share a single 18.5 kW Roots blower for air supply, resulting in a total transport distance of 45.2 meters and total power consumption of 35 kW. This is slightly higher than the FUK630 (30 kW) but significantly lower than traditional chain conveyors (75–90 kW), achieving over 50% energy savings. Additionally, the slightly lower chain speed enhances the lifespan of the conveyor while maintaining complete shell sealing, meeting all environmental standards.

 

Conclusion

While selecting high-performance equipment is essential, the design of the process based on equipment characteristics and site conditions is equally important. The success of the technical solutions depends on how well the equipment features align with the specific situation. Many users prioritize this aspect. Design experience is also invaluable in this process, so it is crucial to choose not only the right equipment but also an experienced manufacturer.

If you are interested in our technical solutions or need further information, please feel free to contact us. We are happy to help!

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Optimizing Roll Press Performance in Cement Grinding

Since the commissioning in May 2007, Company A's cement pre-grinding system has faced frequent failures with the roll press. These issues include low and unstable working pressure on both sides, improper adjustment of the material distribution valve, large particle size of the material exiting the roll press, low hourly output, high grinding energy consumption, and poor overall economic efficiency. This article will share our experiences and improvement measures in controlling the roll press.

 

Problem Analysis and Solutions

1. Causes and Adjustments for Unstable Pressure

Material enters the roll press between the moving and fixed rollers through the upper feeding chute. We found that the material adjusting plate on the moving roller side extended toward the fixed roller. This caused the discharge point to shift toward the fixed roller. As a result, there was too much material on the fixed roller side and almost none on the moving roller side. This uneven distribution led to unstable pressure and ultimately resulted in large particle sizes in the output.

 

To solve this problem, in August 2010, Darko adjusted the material adjusting plate on the moving roller side. We moved its position from the fixed roller side to the outside of the moving roller. We also changed its angle from 45° to 60°. Additionally, we adjusted the initial roller gap to 10 mm. This allowed the material to flow properly between the rollers and distribute evenly, thereby controlling pressure fluctuations.

 

Drawing of moving roller side stopper adjustment plate

2. Causes and Adjustments for Low Working Pressure

After careful observation of the roll press and hydraulic system, we found that the initial pressure on both sides of the system was 6.0 MPa. The equipment could only start when the pressure was loaded to 5.5 to 6.5 MPa. The operators typically increased the pressure to 6.0 MPa and then stopped. Due to the limitations of the initial roller gap, the oil pressure in the hydraulic cylinder was insufficient at 6.0 MPa. Even if the roller gap increased, the pressure could not reach the working pressure of 8.2 MPa.

 

We realized that the initial pressure had a significant impact on the working pressure. Therefore, we adjusted the initial pressure to 6.5 MPa while stabilizing the material flow at the inlet. After this adjustment, the working pressure on both sides increased from 7.4 to 7.8 MPa to 8.2 to 8.6 MPa, resulting in a noticeable reduction in particle size.

3. Adjusting the Material Distribution Valve

During the grinding process, the material forms a cake and discharges from the lower part between the two rollers. With sufficient feeding, the material is effectively pressed. However, the pressing effect on the edge material is not as good as that on the center material. The role of the material distribution valve is to separate well-pressed material from poorly pressed material.

 

We mistakenly believed that a smaller opening of the distribution valve was better and adjusted it to 20%. As a result, the finished product contained coarse material around 10 mm. Upon inspecting the side door of the roll press, we found significant material buildup in the edge chute, which hindered smooth flow. After making further adjustments, we discovered that setting the distribution valve opening to 23% eliminated the material buildup, allowing smooth entry into the return belt.

 

Conclusion

Through these measures, we successfully reduced the average particle size of the clinker from the roll press from 3.81 mm to 1.54 mm. The crushing ratio improved from 4.09 to 10.10. The appearance of the ground material became powdery, and most particles could be easily crushed by hand. Additionally, the hourly output of the ball mill increased by 13.1%, and the system's grinding energy consumption decreased by 16.6%. These improvements significantly enhanced the system's economic efficiency and operational stability. If you face similar issues, please feel free to contact us. We are happy to help!

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How to choose an efficient pulse bag dust collector?

When selecting a pulse bag dust collector, you need to consider multiple factors. This ensures the chosen equipment meets actual production needs and achieves efficient, stable, and economical operation. Here are some key selection steps and important notes:

1. Clarify Working Conditions

1.1 Handling Airflow

Determine the airflow that the dust collector needs to handle. This is the foundation for selection. Airflow directly impacts the specifications and performance of the dust collector. Consider the size of the hood, the distance from the dust emission point, and the filtering wind speed to accurately estimate the required airflow.

 

1.2 Dust Characteristics

Understand the characteristics of the dust, such as particle size, concentration, temperature, humidity, and viscosity. Choose suitable filter materials based on the dust properties, such as polyester, aramid, or fiberglass. For high temperature, high humidity, or highly corrosive dust, select materials that are heat-resistant and corrosion-resistant.

 

2. Determine Dust Removal Efficiency and Emission Standards

2.1 Dust Removal Efficiency

Select a dust collector model that can meet the required efficiency for production. Pulse bag dust collectors typically achieve over 99% efficiency, but this depends on dust characteristics and equipment configuration.

 

2.2 Emission Standards

Clarify the emission standards for the dust collector to ensure compliance with national or local environmental regulations. Set efficiency goals based on these standards and select the appropriate filtering efficiency level.

 

3. Consider Cleaning Methods and Filter Area

3.1 Cleaning Method

Pulse jet cleaning is the most common method for pulse bag dust collectors. Compressed air is injected into the filter bag through a pulse valve for cleaning. Ensure the reliability of the cleaning system and set a reasonable cleaning cycle for maintenance convenience.

 

3.2 Filter Area

Calculate the required filter area based on the handling airflow and filtering wind speed. The size of the filter area directly affects the dust collector's efficiency and investment costs.

 

Two pictures of industrial equipment showing the structure and application of pulse bag dust collector

4. Equipment Layout and Installation

4.1 Installation Location

Determine the installation location and space size for the dust collector based on the layout of the production workshop and equipment placement. Consider the inlet and outlet positions and duct layout to minimize airflow resistance and leakage.

 

4.2 Duct Layout

Design the inlet and outlet positions and duct layout to ensure smooth airflow. If necessary, set up air valves and adjustment devices to control airflow distribution and volume.

 

5. Economic Evaluation

5.1 Cost-Effectiveness

Evaluate the costs of the dust collector, including equipment, installation, operation, and maintenance. Choose a dust collector with high cost-effectiveness to reduce investment costs. Also, assess energy consumption and filter replacement cycles to ensure long-term economic operation.

 

5.2 Energy-Saving Measures

Consider implementing energy-saving measures and efficient cleaning systems to lower operating costs.

 

6. Other Considerations

6.1 Safety Measures

For operations involving toxic or explosive materials, select a dust collector with appropriate safety features. Ensure that the dust collector meets relevant standards for explosion-proof and toxic prevention measures.

 

6.2 Maintenance Convenience

Choose a dust collector that is easy to maintain to reduce maintenance costs and improve equipment reliability. Consider the convenience of filter bag replacement and cleaning system maintenance.

 

Conclusion

In summary, selecting a pulse bag dust collector is a comprehensive process. You must consider working conditions, dust removal efficiency, cleaning methods, equipment layout and installation, economic evaluation, and other important factors. A well-structured selection process can ensure that the dust collector operates efficiently, stably, and economically in practical applications. Choosing the right pulse bag dust collector can enhance production efficiency and effectively protect the environment.For more information or assistance, please feel free to contact us. We look forward to providing you with professional solutions!

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Boiler Baghouse Dust Collector Selection Guide

Boiler baghouse dust collector is key industrial equipment used in various boiler systems. Their main function is to filter and capture particulate matter from flue gases. This process effectively removes dust and improves emission quality, enhancing air quality and aiding environmental protection.

Considerations for Selecting a Boiler Baghouse Dust Collector

When choosing a boiler baghouse dust collector, several factors must be considered to ensure optimal performance and compliance with environmental regulations.

1. Understanding Boiler Specifications

First, assess the boiler's combustion method and rated power. For example, for coal-fired boilers, it is important to understand the type of coal, combustion method, and flue gas volume. This information helps in selecting the right dust collector.

 

2. Following Environmental Policies

Next, be aware of local environmental policies and emission standards. Ensure that the selected dust collector meets these requirements. In areas with strict regulations, you may need a higher-performance dust collector to minimize environmental impact.

 

3. Analyzing Dust Characteristics

Additionally, understanding the physical and chemical properties of the dust is crucial. This knowledge helps in determining the right filter materials and cleaning methods. For flammable or explosive dust, choose a dust collector with explosion-proof features to ensure safety.

 

4. Considering the Process Flow

It is also important to understand the entire process flow. Determine the best location to install the dust collector for optimal effectiveness. In some processes, placing the dust collector before the flue gas discharge can reduce impacts on downstream equipment.

 

5. Impact of Climate Conditions

Moreover, consider local climate conditions such as temperature, humidity, and wind. Choose suitable materials and structures for the dust collector. In high-temperature and high-humidity areas, select collectors with waterproof and corrosion-resistant features to ensure stability and long-term performance.

 

6. Meeting Special Environmental Needs

Finally, for special situations like high temperature, high humidity, or corrosive environments, choose dust collectors with special functions. In corrosive environments, select collectors with anti-corrosion features to extend equipment lifespan.

 

The Boiler Bag Filter is placed in an industrial space, showcasing its importance in maintaining air quality by capturing boiler emissions.

Working Principle of Boiler Baghouse Dust Collectors

Boiler bag filters use the bag filtering principle to capture particulate matter from flue gases, purifying the gas and protecting the environment. After pre-treatment, flue gas enters the dust collector. The gas passes through the bag filter layer, where particles are trapped on the bag surface. The purified flue gas then exits through the outlet.

 

The bags of the dust collectors are made from high-temperature, abrasion-resistant materials. They can withstand the impact and wear of high-temperature flue gases. Additionally, the collectors use a compartmentalized stop-flow pulse jet cleaning method. This method provides long cleaning cycles and low energy consumption.

 

Furthermore, the dust collectors use a top-bag extraction method. During bag replacement, the framework can be easily removed, facilitating operation. The inlet and outlet passages are compactly arranged, leading to low airflow resistance. The equipment is equipped with insulation to prevent low temperatures from causing gas condensation.

 

Conclusion

In summary, when selecting a boiler baghouse dust collector, consider various factors to ensure the equipment's performance and reliability. Make sure it meets environmental requirements. With the right selection and configuration, boiler bag filters can effectively improve emission quality and protect our environment.

Darko looks forward to providing you with professional solutions for boiler baghouse dust collectors! For more information or inquiries, please feel free to contact us!

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Solution to Improve Bulk Steel Silo Loading Speed

Recently, a stone powder company in Shanxi, China, contacted us. They reported that after installing bulk loading equipment on their stone powder steel silo, their loading speed had significantly decreased. Sometimes, it took seven to eight hours to load a single truck, which severely limited their production capacity.

 

Before reaching out to us, this company had tried to communicate with other bulk machine manufacturers. They implemented several measures, such as adding a vibrator to the exterior of the silo cone and installing air supply nozzles and tanks inside. However, these efforts did not yield satisfactory results. Therefore, they requested Darko to provide a solution and sent photos and videos of the on-site equipment.

 

We took their feedback seriously. After carefully analyzing the provided information, we developed a targeted solution. Once we sent our quote, the company quickly signed the contract and made the payment to expedite the order.

 

After shipping the equipment, Darko arranged for technicians to go to the site for installation guidance. Due to limited space and a shortage of installation personnel, the construction took longer than expected. Our technicians stayed on-site for two days to ensure everything was installed correctly before returning.

 

About five days after the modifications were completed, the customer called to express their gratitude. They reported that the loading time for a truck of stone powder had now been reduced to around ten minutes, and they were very satisfied with the results.

 

Key Modifications for the Bulk Steel Silo

1.Installation of Air Supply Boxes:

We installed air supply boxes in suitable positions inside the silo cone, implementing zoned air supply to ensure that the powder material could be evenly fluidized.

 

2.Change of Air Source:

We replaced the original high-pressure air with a Roots blower. Although high-pressure air provided sufficient pressure, its airflow was too small to effectively fluidize the powder material. Additionally, high-pressure air contained moisture, which could cause the powder to clump and block the air supply layer. In contrast, the Roots blower provided a larger airflow and appropriate pressure, and it contained no moisture, making it ideal for this application.

 

3.Shortening of Vertical Pipe Length:

We shortened the vertical pipe length between the cone and the lower discharge gate. The original long vertical pipe could easily form dead zones under prolonged material pressure, which affected the normal flow of materials.

 

Key Modifications for the Bulk Steel Silo

This modification not only improved the customer's loading efficiency but also demonstrated our commitment to addressing customer issues and providing solutions. If you face similar challenges or wish to enhance your production efficiency, please feel free to contact us! We look forward to providing you with professional solutions.

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Optimizing Vertical Grinding Efficiency

In modern industry, the efficiency of vertical grinding systems directly impacts production costs and energy consumption. Here are several effective strategies to reduce power consumption, minimize system resistance, and optimize daily operations.

1. Reduce Main Motor Current

Use mechanical lifting for material handling to lower power consumption more effectively than air lifting. This method reduces the internal circulation load of the vertical mill, enhances grinding efficiency, and decreases equipment resistance. Most vertical mills today have external circulation elevators. However, you need to find the optimal balance between external circulation and system output through ongoing exploration during production.

 

Theoretically, a lower material layer will yield a significantly lower motor current than a higher layer. Therefore, controlling the material layer thickness is crucial. Adjust this thickness using the dam ring. By optimizing the dam ring height, you can achieve a more appropriate thickness for the material layer within the mill. A reduced layer thickness increases the effective force within a unit volume of material, lowers the hydraulic cylinder’s working pressure, and reduces the pressure difference in the mill, leading to lower main motor current.

 

When selecting equipment and designing processes, consider the appropriate ratio of external circulation and the suitable air velocity of the nozzle ring. Ensure that the capacity of the external circulation elevator matches the system requirements. Additionally, controlling the air volume is essential to prevent excessive fine powders during discharge.

 

2. Lower System Resistance

The energy consumed by the circulating fan is closely linked to wind pressure, airflow, and fan efficiency. When system resistance is high, fan efficiency decreases, leading to increased current draw. Therefore, reducing system resistance is essential for enhancing fan efficiency and lowering current consumption.

 

Identify the primary sources of resistance by installing pressure detection devices at key locations: the hot air inlet, classifier outlet, cyclone outlet, and nozzle ring outlet. Comparing pressure differentials at these locations will help pinpoint the main sources of resistance.

3. Address System Air Leaks

Air leaks in the vertical mill system primarily occur in the mill and the dust collector. Ensure that the leak rate remains below 8%. Key leak sources include lock air devices at the mill inlet, roller seals, connection flanges, and expansion joints. In dust collectors, significant leaks often occur at the casing cover and connection flanges.

 

Air leaks increase current consumption by the fan, escalate energy costs, and potentially impact the mill’s output. Therefore, timely management of air leaks is vital for improving system efficiency.

4. Daily Operational Insights

Control the particle size of incoming material, typically within 3% to 5% of the roller diameter. After wear occurs on the roller sleeves and grinding table liners, adjust the gap between the roller and the grinding table. Regularly check the accumulator pressure, maintaining it within 60% to 70% of the roller's working pressure.

 

Higher grinding pressure is not always beneficial. If the output reaches a critical value, further increases in motor current will worsen energy consumption and jeopardize safe operation. Therefore, determine the optimal pressure based on actual production conditions. Additionally, maintain the outlet gas temperature around 85°C to stabilize grinding and classification efficiency.

Two combined scenes of a vertical roller mill, showcasing its operational setup and components in a cement production environment.

5. Central Control Operation Considerations

Grinding Pressure: Aim for a grinding pressure that does not exceed a certain critical value. Further increases can elevate the main motor current and energy consumption. Develop a curve that correlates pressure with output to optimize this aspect.


Outlet Gas Temperature: Keep the outlet gas temperature stable at around 85°C. Deviations can significantly impact grinding and classification efficiency.


Valve Settings: Open all valves, including the inlet air valve, circulation air valve, fan outlet valve, and bypass air valve, to minimize system resistance. To check if the bypass valve should remain open, close it and observe the inlet negative pressure. If it increases, re-open the bypass valve.


Negative Pressure Control: Maintain the negative pressure at the tail end of the dust collector within -500Pa. This pressure affects the volume of supplementary air entering the mill and reduces the current of the exhaust fan. If the negative pressure does not decrease, monitor the site and instruct the central control to gradually lower the tail discharge, addressing any areas where dust escapes.


Control Startup and Shutdown Times: Ensure that the time from starting the first auxiliary equipment to feeding the mill does not exceed 4 minutes. During shutdowns, if no maintenance is required, there is no need to empty the material from the mill.

By implementing these strategies, companies can significantly enhance the efficiency of their vertical grinding systems while lowering energy consumption and optimizing production processes. If you have any questions or need assistance in improving the efficiency of your vertical grinding system, please feel free to contact us. We are here to provide you with professional solutions!

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Nantong Darko Building Materials Machinery, a leading manufacturer and supplier in China, specializes in R&D, design, manufacturing, and installation of solutions for desulfurization, denitrification, dust removal, and environmental protection projects, as well as slag micro powder and powder grinding production lines.

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