Sandstone aggregate production line is one of the most upstream production lines in national infrastructure, which provides indispensable raw materials for various types of infrastructure. However, in the production process of sand aggregate, most of the production lines can not meet the original design needs, and at the same time, there will be some problems more or less. Below for you to explain the six common problems, and the corresponding solutions. This will be helpful to the design and selection of production line, so as to avoid the influence of wrong concepts on the later production line operation.
I. Equipment Selection
In the process of investing in production line, many investors directly use a set of equipment needed by other production lines, regardless of the differences and characteristics of raw materials.
However, some equipment is not suitable, such as crusher is divided into hammer type and counterattack type. In a short time, the required equipment output can be achieved barely. After the equipment is put into operation for a period of time, a large number of problems have appeared one after another, such as serious wear and tear of equipment wear parts, frequent replacement, increased power consumption, reduced output, increased maintenance costs and so on.
Such problems are generally difficult to adjust by changing the process. Replacing equipment is the only solution at present.
II. Material bin or silo
1. Coarsely broken feeding bin
The common problem is that the side outlet of the warehouse is designed as a rectangular “door” structure. There is a dead angle between the warehouse and the outlet. The material discharging is not smooth enough. The bulk material is easy to accumulate here, which affects the normal feeding.
Improvement measures: Place a excavator beside the feeding port to clean up the accumulated material at any time; in the off-season of the market, transform the side outlet of the feeding bin into trapezoidal “inverted eight” structure in order to eliminate the dead corner of the accumulated material.
2. Medium and Fine Breakage and Sand Buffer Silo
The common problem is that the bottom of the warehouse is designed as a flat-bottomed steel warehouse structure, because the overall material pressure at the bottom of the warehouse is large, during the operation of the production line, there will be serious deformation and subsidence at the bottom of the steel warehouse, which will lead to potential safety hazards.
Improvement measures: reinforcement of the bottom structure; design units try to avoid using flat-bottomed steel silo structure in the design, if inevitable, try to choose the bottom of the silo as concrete structure.
3. Product Storage
Product warehouse generally adopts concrete storage form, which has large storage capacity and is safe and stable. But some enterprises choose steel warehouse to store sand and aggregate, so it is necessary to regularly check the wear condition of steel warehouse and carry out wear-resistant treatment.
4. Stone Powder Storage
The common problems are the wetness of stone powder produced in rainy weather and the difficulty of discharging stone powder from paste storehouse.
Improvement measures: Install several air guns below the reservoir body, and use compressed air to loosen the stone powder in the reservoir; design units should try to control the stone powder storehouse not to be too large in design, and design flow aids, inflatable boxes or air guns in the cone part of the reservoir.
III. Material transshipment gap
1. Rough breaking outlet
Coarse breaking equipment has a certain thickness of concrete foundation, and the gap between the outlet and downstream conveyor belt is large, and after coarsening, the bulk of the material is less than 300 mm. These stones are directly hit on the belt conveyor, and there will be phenomena such as breaking the buffer roller and tearing the conveyor belt by the roller carrier.
Improvement measures: The buffer roller of downstream belt conveyor is replaced by buffer bed, and the structure of discharge chute is changed to reduce the impact on downstream equipment. In addition, if the drop is very large and the layout space permits, the impact on downstream equipment can also be reduced by adding buffer feeder (such as vibration feeder).
2. Vibrating Screen Feed Gate
In order to ensure sufficient overhaul space above the vibrating screen, or to separate the material between the conveying equipment and the vibrating screen “one to two”, there will be a large drop when the material enters the vibrating screen, and the impact of the material on the screen plate in operation will cause rapid wear and tear of the screen plate.
Improvement measures: adding waste belt conveyor tape to the impact position of the screen plate, and rationally adjusting the slide form to reduce the impact and wear of the screen plate.
IV. Environmental problems
After the formal design of production lines, environmental protection can basically meet the requirements of the national standard, but individual production lines in the vicinity of the second break impact crusher, finished goods loading garage near bulk dust.
Improvement measures: 1) Firstly, according to the number and location of dust collection points, the selected dust collector specifications, for the dust near the impact crusher, if the designed dust collector air volume is enough, then setting dust collection points before and after the crusher discharge points can effectively reduce the dust raised here. 2) for the fugitive dust near the bulk of the finished product store, if the air volume of the designed dust collector is sufficient, and the bulk dust collector is collected through the top dust collector, a centrifugal fan can be added between the connecting air pipe of the bulk machine and the top of the storehouse to enhance the dust collecting efficiency of the top dust collector, and the addition of water spray dust near the unloading port of the bulk machine can effectively reduce the dust collection efficiency. Fugitive dust.
V. Collection and transportation of stone powder (< 0.075mm)
The dust collecting powder of the production line is collected directly on the downstream conveyor belt, so there are some problems, such as repeated reverse transportation, secondary dust, high content of stone powder in the product, and so on. In addition, there are dust spills caused by improper sealing of the belt conveyor’s guide trough and rain cover, or rain leaks in cloudy and rainy days, which make the stone powder moist and eventually cause the phenomenon of paste storage.
In the production line, stone powder is conveyed by air conveying chute. There is a problem that the permeable layer of the chute is sealed when stone powder is wet in rainy days, and the material can not be conveyed.
Improvement measures: dust collected by dust collectors in the production line or at least in the later stage of the process will be transported to the stone powder storehouse by zipper and hoist equipment separately.
VI. Other Issues
1) When the vibration screen starts, the load is large, which easily causes the gear wear or damage of the exciter seriously. Improvement measures: Properly adjust the installation angle of the equipment, and increase the frequency converter to start slowly.
2) The inaccuracy of the basic data collected during the design results in the small selection of individual conveyor belts, which affects the production capacity of the production line. Improvement measures: by replacing the drive system to improve the belt speed of the belt conveyor, and then improve the conveying capacity of the belt conveyor.
3) Dust leak and material leak at the connection between the import and export of vibration equipment. The canvas soft connection used is not durable and frequently replaced. Improvement measures: Soft connection is made on site with waste belt conveyor tape, which has long service life and good sealing effect.
Luoyang Building Material and Architectural Design and Research Institute is a professional building material and building double-grade design and research institute. It has more than 20 years’experience in mineral material research. According to the needs of customers, our institute can provide a series of services, such as feasibility study report, design, general package, production improvement, intelligent transformation, etc. It can provide customers with solutions tailored to local conditions, scientific and reasonable production line engineering. Art can not only meet the output requirements of process design, but also save resources, save energy and protect environment. It can also greatly reduce the failure rate of equipment, reduce the loss of equipment and the replacement frequency of spare parts, and realize the continuous growth of economic benefits.