屏蔽泵基本知識

1、1,冷卻過程 COOLING PROCESS,冷卻過程是在一定的時間內(nèi)將產(chǎn)品 的溫度和水分平衡到標(biāo)準(zhǔn)質(zhì)量狀態(tài) 的一種熱交換過程。 The process balanced temperature and humidity of the product to standard quality within limited time,

2、定義 / Definition,2,溫度平衡 TEMPERATURE EQUILIBRIUM,熱通過蒸發(fā)過程而變成水蒸汽 HEAT USED FOR EVAPORATION PROCESS TO VAPOR熱通過熱的傳播過程傳遞到冷卻介質(zhì)上 HEAT TRANSFER TO COOLANT (MOIST AIR) THROUGH THERMAL DIFFUSION PROCESS,3,-

3、毛細管作用造成的液體流動 LIQUID MOVEMENT DUE TO CAPILLARITY滲透力造成的液體流動 LIQUID MOVEMENT DUE TO OSMOTIC FORCE- 水份差異造成的液體流動（液體擴散作用） LIQUID MOVEMENT DUE TO MOISTURE CONCENTRATION DIFFERENCE (LIQUID D

4、IFFUSION),溫度平衡 TEMPERATURE EQUILIBRIUM,4,- 重力造成的液體流動 LIQUID MOVEMENT DUE TO GRAVITY- 水份差異造成的蒸汽流動（蒸汽擴散作用） VAPOR MOVEMENT DUE TO MOISTURE CONCENTRATION DIFFERENCE (VAPOR DIFFUSION)-

5、 溫度差異造成的蒸汽流動（熱擴散作用） VAPOR MOVEMENT DUE TO TEMPERATURE DIFFERENCE (THERMAL DIFFUSION),溫度平衡 TEMPERATURE EQUILIBRIUM,5,冷卻過程 Cooling Process,1. 蒸發(fā) EVAPORATION2. 熱擴散

6、 THERMAL DIFFUSION3. 機械或化學(xué)力造成的液體流動 Liquid movement by Mechanical & Chemical Force4. 機械或化學(xué)力造成的蒸汽流動 Vapor movement by Mechanical & Chemical Force,6,顆粒料冷卻 PELLET COOLING,它是通過蒸發(fā)和熱擴散過程，使料的溫度和環(huán)境空

7、氣相平衡， 從而降低顆粒料溫度和水份（粉狀料經(jīng)過蒸汽調(diào)質(zhì)與制粒過程而 增加的溫度與水份部分）的一種過程。 The process of decreasing temperature and moisture from pellets (which increase by mash conditioning with steam and pelleting pro

8、cess.) 環(huán)境空氣進入冷卻器，在一定的時間內(nèi)與顆粒料外表面接觸，直到顆粒料溫度不超過環(huán)境溫度 +5 oC以上, 顆粒水份不超過 12%. by temperature and humidity balance with ambient air through the evaporation and thermal diffusion process, the ambi

9、ent air is brought in contact with the outer surface of the pellets in the cooler within limited duration until the pellet Temperature is less than or equal the ambient temperature +5 oC and the p

10、ellets moisture must not be exceed 12%.,7,,,,,,,,,,,,,,Cool Air,Warm Air,Vapor,Vapor,,,,,,Water,Heat,溫度降低原因有： Temperature Decrease by蒸發(fā)(熱用于將液體變成蒸汽）Evaporation (heat used for change liquid t

11、o vapor)熱擴散(熱傳遞出去) Heat Diffusion (heat transfer out)水份降低原因有： Moisture Decrease by蒸發(fā) (蒸汽脫離) Evaporation (vapor move out)運動力 (液體脫離) Kinetic Force (liquid move out)

12、,顆粒料冷卻 PELLET COOLING,8,顆粒料冷卻 PELLET COOLING,40 °C12%M,32 °CAmbient Temp.,,,,,,,Heat Diffusion,32 °C11%M,32 °CAmbient Temp.,Heat Balance,,Surface14%M,,9,,顆粒料冷卻特性 PELLET COOLING CHARACTE

13、RISTIC,臥式冷卻器 / CROSSFLOW COOLER,,,,,,,,,,,Air Flow,Product flow,Air Inlet Temp,Air Outlet Temp,Pellet Begin Temp,Pellet End Temp,10,,逆流式（或立式）冷卻器 / COUNTERFLOW COOLER,,,,,,Air Flow,Product flow,Air Inlet Temp,Air Outlet

14、Temp,Pellet Begin Temp,Pellet End Temp,,,,顆粒料冷卻特性 PELLET COOLING CHARACTERISTIC,11,顆粒料冷卻曲線圖 PELLET COOLING PROFILE,EvaporationStage,Thermal Diffusion,Ambient Temperature 30 °CRelative Humidity 70 %,12,Evaporat

15、ionStage,Liquid & VaporMovement,Ambient Temperature 30 °CRelative Humidity 70 %,顆粒料冷卻曲線圖 PELLET COOLING PROFILE,13,冷卻過程影響因素 The factors effected to cooling process.,顆粒狀態(tài) Pellets - 溫度

16、 Temperature - 水份 Moisture - 密度 Density - 大小和形狀 Size & Shape - 油脂噴涂 Fat Coated,14,2. 環(huán)境空氣 A

17、mbient Air - 溫度 Temperature - 相對濕度 Relative Humidity - 風(fēng)量 Volume - 蒸氣壓力 Vapor Pressure - 空氣中水份與蒸氣濃度 Water content and vap

18、or content in the air顆粒料在空氣中的流動時間 Time that pellets move within the air,冷卻過程影響因素 The factors effected to cooling process.,15,EVAPORATION,THERMAL DIFFUSIONLIQUID& VAPOR MOVEMENT,PRODUCT IN,PRODUCT OUT,MOIST A

19、IR IN,MOIST AIR OUT,16,影響動物消化的因素 Animal digestion factors,1. 蒸發(fā) Evaporation - 顆粒溫度 Pellet temperature - 顆粒濕度 Pellet moisture - 油脂噴涂 Fat coating - 風(fēng)量

20、 Air volume - 蒸氣壓力 Vapor pressure,17,2. 熱傳遞 Heat transfer - 顆粒溫度 Pellet temperature - 顆粒密度 Pellet density - 顆粒大小與形狀 Pellet s

21、ize and shape - 油脂噴涂 Fat coating - 風(fēng)量 Air volume - 空氣溫度 Air temperature - 顆粒停留時間 Pellet dwell time,影響動物消化的因素 Animal digestion factors,18

22、,3.4 因機械和化學(xué)作用造成的蒸氣/液體流動 Vapor / liquid movement by mechanical and chemical force - 顆粒水份 Pellet moisture - 顆粒密度 Pellet density - 顆粒大小與形狀 Pellet size

23、 and shape - 風(fēng)量 Air volume - 空氣相對濕度 Relative humidity of air - 空氣蒸發(fā)壓力 Air vapor pressure - 空氣中水份與蒸氣濃度 Moisture and vapor air content - 顆粒停留時間

24、 Pellet dwell time,影響動物消化的因素 Animal digestion factors,19,冷卻過程需要的風(fēng)量 Air Volume Required for Cooling Process,為降低1000 KGs.顆粒料溫度與水分: 進料溫度 90 °C >> 出料溫度 33 °C進料水份 15%

25、 >> 出料水份 12%采用30 °C 的環(huán)境空氣冷卻器空氣出口溫度 45 °CTo decrease temperature and moisture of 1000 KGs.-pellets Pellets Inlet Temp. 90 °C >> Pellet Outlet Temp. 33 °CPellets

26、 Inlet Moisture 15% >> Pellet Outlet Moisture 12%By using the ambient air at 30°C Outlet temperature from cooler 45 °C,冷卻過程空氣需要量經(jīng)驗計算Practical calculation for finding air volume uses for

27、cooling process,20,將顆粒水分從15% 降低到 12%:水分 15% 意味著顆粒 1000 KGs. 包括水 150 KGs.和干料 850 KGs.水分12%意味著顆粒 100 KGs. 由干料 88 KGs. 和水 12 KGs.組成.故此, 如干料有850 KGs. 水則有 12 x 850 /88 = 116 KGs.那么蒸發(fā)掉的水就是 150-116 = 34 KGs.To decrea

28、se moisture from 15% to 12%Moisture 15% means the pellets 1000 KGs. Consist of water 150 KGs.and dry component 850 KGs.Moisture 12% means the pellets 100 KGs. Consist of dry component 88 KGs. and water 12 KGs.So

29、,If there are dry component 850 KGs. water 12 x 850 /88 = 116 KGs.Then must be evaporated water 150-116 = 34 KGs.,冷卻過程空氣需要量經(jīng)驗計算Practical calculation for finding air volume uses for cooling process,冷卻過程空氣體積需要量 Air Vol

30、ume Required for Cooling Process,21,冷卻過程空氣體積需要量 Air Volume for Cooling Process,自顆粒傳遞的熱: / Heat transfer from pellets: 由: Q = mc (t2 - t1)Q = 1000*1.8*(33 - 90)

31、 = -102,600 KJ.將 1 KG.水蒸發(fā)變成蒸氣需要的熱量 = 2,360 KJ.Heat used to evaporate water 1 KG.to vapor故; 蒸發(fā) 34 KGs.水需要的熱量 So; Heat used to evaporate water 34 KGs..

32、 = 34*2,360 KJ. = 80,240 KJ顆粒必須傳遞的熱量 Heat must be transferred from pellets = 80,240 - 102,600= 22,360 KJ.,,22,空氣體積需要量: / Air volume required:由 Q =

33、 mc (t2 - t1)故; 22,360 = m*1*(45 - 30)空氣重量需要量 (m). / Air weight required(m) = 22,360 / 15 = 1,490 KGs單位空氣體積重量 / Weight of air by volume = 1.2 KGs./ 1 m3故; 空氣體積需要

34、量 / So; Air volume required = 1,490 / 1.2 = 1,240 m3估計的空氣體積需要量 ? 1,200 m3/ton-顆粒Estimated air volume require ? 1,200 m3/ton-pellets,,冷卻過程空氣體積需要量 Air Volume for Cooling Process,23,顆粒位置與空氣流量對環(huán)境空氣

35、與顆粒間的蒸發(fā)和熱擴散的影響Evaporation and Thermal Diffusion Effected between Ambient Air and Pellets at Different Layer And Different Air Volume,,24,冷卻器后顆粒溫度、水份與空氣流量之間的關(guān)系 Relation of Temperature, Moisture of pellets after c

36、ooler and Air Volume,低溫,低水份Low Temp., Low Moisture,,,,,高溫，高水份Highest Temp., Highest Moisture,< 800 m3/t,1000 m3/t,高溫，高水份High Temp., High Moisture,低溫，高水份Low Temp., Higher Moisture,1200 m3/t,1500 m3/t,> 1800 m3/

37、t,正常溫度，正常水份Normal Temp., Normal Moisture,25,空氣流速過高的影響 Effected from Excessive Air Velocity,滑動式排料機構(gòu)的適宜氣流速度: 1.2 m/s (在冷卻機最大產(chǎn)能上)翻板式排料機構(gòu)的適宜氣流速度: 1.3 m/s

38、 (在冷卻機最大產(chǎn)能上),Appropriate air velocity for Slide Grid Discharge System : 1.2 m/s at max cooler capacityAppropriate air velocity for Swivel Valve Discharge System :1.3 m/s

39、 at max cooler capacity,26,不能排料或排料不連續(xù); Cannot discharge pellets from cooler or inconsistent discharge 顆粒開裂或風(fēng)道吸入粉塵; Cracked pellets or dust is sucked up to air duct. 料層一直上下移動,使顆粒料在冷卻器中

40、停留時間變化不定。 因而造成顆粒料排出冷卻器后有效水份和溫度不均。 Pellets layer move up and down all the time and cause the time of pellets in cooler are different. So these effect moisture and temperature after discharge cooler are

41、 uneven. 引起料層出現(xiàn)空洞，使多數(shù)冷卻空氣由此穿過。 Cause of the holes in the product layer. So most air is flowed through these hole,空氣流速過高的影響 Effected from Excessive Air Velocity,27,逆流式冷卻器的主要部件 Important component of COUNTER

42、FLOW COOLER,1. 喂料閉風(fēng)器 INLET ROTARY VALVE2. 頂蓋 / HOOD3. 分料器 / PRODUCT DISTRIBUTOR4. 冷卻室 / COOLER BIN5. 排料門 / DISCHARGE GATE6. 支架 / SUPPORT FRAME7. 集料斗 / COLLECTING HOPPER8. 排料傳感器 DISCHARGE LEVEL SE

43、NSOR9. 溢料傳感器 OVERFLOW LEVEL SENSOR10.裝有著火調(diào)溫器的出風(fēng)管 AIR OUTLET WITH FIRE THERMOSTAT,,28,逆流式冷卻器的附屬部件 Accessory part of COUNTERFLOW COOLER,29,固定分料器 / STATIONARY PRODUCT DISTRIBUTOR,分料器 PRODUCT DISTRIBUTOR,1

44、. 在上下與水平方向上調(diào)節(jié)分料器以使顆粒料進入冷卻機箱體時分散均勻。 Adjust product distributor vertically and horizontally for distribute pellets to the cooler housing.2. 調(diào)節(jié)分料器中間間隙，以控制顆粒料在中間位置和四周的數(shù)量。 Adjust the gap of product distributor fo

45、r control pellets quantity at the middle and the corner of cooler,30,旋轉(zhuǎn)分料器 / ROTATING PRODUCT DISTRIBUTOR,分料器 PRODUCT DISTRIBUTOR,31,旋轉(zhuǎn)分料器 ROTATING PRODUCT DISTRIBUTOR,調(diào)節(jié)分料器(1)的角度使顆粒料流經(jīng)散料器進入冷卻器。Adjust the ang

46、le of the product distributor(1) for control the distribution of pellets through the cooler housing.分料板之間的距離可以靠松掉螺栓(2)來調(diào)節(jié)。下端的間隙應(yīng)大于上端的間隙。The gap between the distributor trays can be adjusted by releasing the bolts (2)

47、and sliding the trays. The lower gap should be larger than the upper gap.,32,滑動式排料門 SLIDE GRID DISCHARGE GATE,33,頂部框（1）為固定框，中間框（2）為活動框由電機驅(qū)動, 下面的工作框(3)的位置改變依靠氣缸驅(qū)動TOP GRID(1) STATIONARY GRID, MIDDLE GRID(2) MOVABLE G

48、IRDDRIVE BY MOTOR, LOWER GRID(3) CHANGE POSITIONDRIVE BY PNUEMATIC CYLINDER,排料位置 / DISCHARGE MOVEMENT,不排料位置 / CLOSED POSITION,清料時，框 (3) 向右移動CLEAN OUT (3) MOVE TO RIGHT,動力切斷時，框 (3) 移動到左邊POWER FAIL (3) MOVE TO LEFT,,,,

49、,滑動式排料門 / SLIDE GRID DISCHARGE GATE,34,Control circuit,35,翻板式排料門 SWIVEL VALVE DISCHARGE GATE,36,關(guān)閉位置CLOSED POSITION,打開位置OPEN POSITION,清料位置CLEAN OUT,翻板式排料門 SWIVEL VALVE DISCHARGE GATE,37,翻板式排料門 SWIVEL VALVE DISC

50、HARGE GATE,38,關(guān)閉位置CLOSED POSITION,打開位置OPEN POSITION,清料位置CLEAN OUT,翻板式排料門 SWIVEL VALVE DISCHARGE GATE,39,Timer for delay discharge time of the next stroke.,When “Clean Out” Circuit will force ‘Open’ solenoid.,控制電路

51、Control circuit,40,溢料料位傳感器 OVERFLOW LEVEL SENSOR 當(dāng)顆粒料觸到這個傳感器執(zhí)行部位時，控制電路切斷制粒機喂料器。When the product reaches the active part of this sensor, the control circuit will switch off the pellet mill feeder,排料料位傳感器 DISCHARGE

52、LEVEL SENSOR當(dāng)顆粒料觸到這個傳感器執(zhí)行部位時，控制電路接通排料門進行排料。調(diào)節(jié)排料料位傳感器高度，可以影響到顆粒料在冷卻器里的停留時間。如果蒸發(fā)過程獲得足夠的進風(fēng)量，顆粒水份和溫度就會變化。When the product reaches the active part of this sensor, the control circuit will switch on the cooler discharge gate

53、.By adjust the discharge level sensor this effect to the time that pellet be in the cooler. If there are enough air volume for evaporation process ,then the pellets moisture and temperature changed,OVERFLOW SENSOR,DI

54、SCHARGE SENSOR,ROTARY PADDLE LEVEL SENSOR,料位傳感器 Level sensor,41,由于制粒機或熟化機過熱，冷卻器里可能會發(fā)生著火情況。探測到著火溫度時，著火調(diào)溫器就會停止排風(fēng)風(fēng)機和關(guān)閉風(fēng)閘。Due to overheating in a pellet mill or expander a fire might occur in the cooler. Upon fire the

55、thermostat stops the exhaust fan and closes damper,通常，應(yīng)按將著火控制溫度點調(diào)整到比出風(fēng)口溫度約高出 10°C 但不超過 75 °CNormally, set point temperature should more than air outlet temperature about 10°C or not over 75 °C,著火調(diào)溫

56、器 / FIRE THERMOSTAT,42,逆流式冷卻器的調(diào)整與操作 Adjustment and Operation COUNTERFLOW COOLER,1. 運行前的調(diào)整 Adjustment before operation2. 分料器調(diào)整 Pellet distribution adjustment3. 顆粒在冷卻器內(nèi)停留

57、時間 Dwell time of pellet in cooler4. 排料速度 Pellet discharge rate5. 進風(fēng)量控制 Air volume control6. 維護保養(yǎng) Maintenance,43,運行前的調(diào)整 Adjustme

58、nt before Operation,滑動式排料門 / SLIDE GRID DISCHARGE GATE,在料門的關(guān)閉位置上，將中間框驅(qū)動凸輪的停止排料位置調(diào)節(jié)至行程（B）終端松動螺栓 (9, 10), 將限位開關(guān)（4）移動到要求位置。 Adjust the stopped position of driven cam of the middle grid to the end stroke(B) at t

59、heclose position of the gate , Loose screw (9, 10), move limit switch (4) to the required position將中間框驅(qū)動凸輪的停止排料位置調(diào)節(jié)到與頂部框相配，使之能 防止中間框產(chǎn) 生積料。松下螺母 (11), 拉長或縮短這段距離，使中間框左上端靠近頂部框左下端。 Adjust the stopped

60、position of the middle grid in proportion with the top grid to defendthe remaining product on the middle grid, Loose nut (11), extended or shorten the range until the top left of the middle grid close to the bottom l

61、eft of the top grid,44,3. 調(diào)節(jié)下部框位置使其與中間框位置相配。 Adjust the position of the lower grid in proportion with the middle grid - 為使運行正常，清料柱塞(5) 須縮進, 動力切斷柱塞（19）須外伸。 For normal operation the clean out piston(5) must

62、 be shrink, the power fail piston(19) must be extend - 順時針方向轉(zhuǎn)動手輪(13) 到底（靠近螺母15）, 在此位置，下部框離開中間框，如 細節(jié)圖A 所示。如果從冷卻器里面垂直看下去，應(yīng)看不到光線通過，但沿 450 方向則可看見光線通過。 Turn the handwheel(13) in the clockwise direction to

63、the end (close to nut 15), at this position the lower grid is off from the middle grid as shown in detail A. if see from inside cooler in the vertical direction, can not see the light pass through the c

64、ooler, but in 450 direction can see the light pass through,運行前的調(diào)整 Adjustment before Operation,滑動式排料門 / SLIDE GRID DISCHARGE GATE,45,3.將下部框的位置調(diào)節(jié)至與中間框位置相配. / Adjust the position of the lower grid in proportion with the m

65、iddle grid - 正常運行時，下部框的位置不應(yīng)靠近主（ Stop Boss bar）。下部框的位置應(yīng)離開主止動塊，如細節(jié)圖B所示。 In normal operation,the lower grid position must not be close to the Stop Boss bar. The lower grid position is off from the Stop Bo

66、ss bar as show in detail B. - 不生產(chǎn)時，動力切斷柱塞（19）縮進，使下部框移動到靠住主止動塊，致使中間框各處均不發(fā)生漏料。 When the plant is blacked out, the piston Power Fail(19) is shrank and effect to the lower grid move close to the Stop Boss

67、bar , in all position of the middle grid to protect the product leak from cooler4.將止動塊(8)的位置調(diào)節(jié)至與下部框相配, / Adjust the position of the Stop Block(8) in proportion with the lower grid. - 當(dāng)冷卻器放空（清料）時，柱塞(5)伸出,薄片 (16) 須離

68、開止動塊（8） 1 mm。 When the cooler has been emptied(Clean Out). The piston(5) extended, Sheet(16) must be 1 mm off from the Stop Block(8),運行前的調(diào)整 Adjustment before Operation,滑動式排料門 / SLIDE GRID DISCHARGE GATE,4

69、6,液壓驅(qū)動翻板式排料機構(gòu) / SWIVEL VALVE DISCHARGER HYDRAULICALLY DRIVEN,用筆左右轉(zhuǎn)動開口（4）檢查柱塞（5）的方向，以此 手動操作控制閥 Operate control valve manually by pushing a pen in the right or left opening (4) to test the direction of the p

70、iston (5) 推緊筆端,頂進開口(4)10秒,在外接壓力表上觀察釋壓 閥的壓力。壓力的調(diào)整必須使柱塞能完全打開與關(guān)閉 (80 Bars)。 Push the pen on one side into opening(4) for 10 seconds and read on the manometer the pressure of the pressure relief

71、valve. The pressure must be adjusted in such a way that the piston opens and closes completely (80 Bars) 轉(zhuǎn)動順或逆時針方向轉(zhuǎn)動旋鈕（1）可以改變溢流壓力 大小，調(diào)整后應(yīng)用鎖緊螺母（2）鎖緊旋鈕。 The overpressure can be changed by turning knob (1)