粉碎技术

12/12/2017,CPF Feedmill KnowledgeBase,1,粉碎技术PARTICLE SIZE CONTROL,SAKCHAI BOAMOON,12/12/2017,CPF Feedmill KnowledgeBase,2,颗粒尺寸控制Particle Size Control,1. 减小原料尺寸的方法 Raw material size reduction锤片粉碎机粉碎 Grinding with HAMMER MILL对辊式粉碎机粉碎 Grinding with ROLLER MILL微粉机粉碎 Fine Grinding with PULVERIZER2. 减小颗粒尺寸的方法 Pellets size reduction破碎机破碎 Crumbling with CRUMBLER齿式破碎机破碎 Crumbling with CRUSHER,12/12/2017,CPF Feedmill KnowledgeBase,3,颗粒尺寸控制Particle Size Control,原料尺寸的筛选 Raw material size selection通过初清筛分离杂料 Contaminating separation by SCALPER 通过旋转粉碎筛分离杂料 Contaminating separation by ROTARY SCREENER通过分级筛分离杂料与挑选尺寸 Contaminating separation and size selection by SIFTER,12/12/2017,CPF Feedmill KnowledgeBase,4,颗粒尺寸控制Particle Size Control,饲料清理 Feed Cleaning 通过旋转清理筛分离杂质 Contaminating separation by ROTARY SCREENER2. 通过多层分级筛挑选尺寸 Feed size selection by MULTI-DECK SCREENER3. 通过颗粒分级筛分离杂料与粉料 Contaminating separation and dust separation by PELLET SIFTER,减小颗粒尺寸技术PARTICLE SIZE REDUCTION TECHNOLOGY,粉碎定义 Grinding Definition粉碎或降低尺寸的方法 Methods of Grinding or Size Reduction粉碎机的种类 Type of Grinder粉碎过程在饲料厂的重要性 The importance of grinding process in feed mill锤片粉碎机加工 Hammer mill Process工作原理 Basic Operation Concepts主要零件 Important parts影响粉碎的因素 Factors effected to grinding process操作要领 Tuned up for operation维护保养 Maintenance故障处诊断 Troubleshooting对辊粉碎机加工 ROLLER MILL Process破碎机加工 CRUMBLING Process,粉碎定义 Grinding Definition,粉碎 减小颗粒尺寸 GRINDING PARTICLE SIZE REDUCTION粉碎是指利用外力减小谷物或原料的颗粒尺寸,以便控制成品的细度和质量的加工过程 Grinding Process refers to process that grains or materials size reduced by force and able to control the fineness and quality of finished ground products.,粉碎方法(怎样粉碎原料) METHODS OF GRINDING,撞击 (IMPACT)挤压 (COMPRESSION)剪切 (SHEAR,CUTTING)碾磨 (ATTRITION),12/12/2017,CPF Feedmill KnowledgeBase,8,剪切CUTTING (SHEAR),挤压COMPRESSION,碾磨ATTRITION,撞击IMPACT,粉碎物料的主要方式MAIN METHOD OF SIZE REDUCTION,12/12/2017,CPF Feedmill KnowledgeBase,9,利用高速旋转的锤片来击碎物料颗粒OBJECT IS IMPACTED (HIT) BY THE MACHINE PART- USUALLY A “ HAMMER ” AT A HIGH ENOUGH VELOCITY TO BREAK THE PARTICLES 利用撞击原理的粉碎机有 EXAMPLES OF “IMPACT” MILLS - 锤片式粉碎机 HAMMERMILL - 超微粉碎机 PULVERIZER - 球磨粉碎机 BALL MILL - 笼式粉碎机 CAGE MILL,撞击 IMPACT,12/12/2017,CPF Feedmill KnowledgeBase,10,物料在两个机械零件之间被挤压OBJECT IS COMPRESSED BETWEEN TWO MACHINE PARTS 利用挤压原理的粉碎机有 EXAMPLES OF COMPRESSION - 低剪切对辊粉碎机 LOW SHEAR ROLLER MILL - 单辊和双辊齿式破碎机 SINGLE AND DUAL ROTOR CRUSHERS - 锷式破碎机 JAW CRUSHER - (盘式、锥式）粉碎机 DISC MILL , CONE MILL , BURR MILL,加工前BEFORE COMPRESSION,加工后AFTER COMPRESSION,挤压 COMPRESSION,12/12/2017,CPF Feedmill KnowledgeBase,11,物料颗粒在高速气流中相互撞击OBJECTS IMPACT EACH OTHER IN AN AIRSTREAM EXAMPLES OF ATTRITION MILLS 喷磨机 JET MILL 碾磨机 ATTRITION MILL,加工前BEFORE,加工后AFTER,碾磨 ATTRITION,12/12/2017,CPF Feedmill KnowledgeBase,12,物料被切刀或在两个牙齿间被切碎OBJECT IS CUT WITH SHARP KNIFE OR BETWEEN TWO SHARP TOOTH 利用剪切原理的粉碎机有 EXAMPLES OF CUTTING MILLS - 对辊粉碎机 ROLLER MILL - 破碎机 CRUMBLER - 破饼机 GRANULATOR - 切碎机 SHREDDER - PARTICLE-IZER,加工前BEFORE CUTTING,加工后AFTER CUTTING,剪切 CUTTING,12/12/2017,CPF Feedmill KnowledgeBase,13,不同设备与物料粉碎颗粒分类图表Equipment Reference Chart,Beach Sand,Talc,Flour,Pulverized Coal,Ground Limestone,Spices,Visible to Eye,Laser Analysis,Cyclone,Filter Collectors,Dust,Hammermills,Granulators,CrushersParticle-izers,Shredders,Air Swept Pulverizer,12/12/2017,CPF Feedmill KnowledgeBase,14,Any Question?,12/12/2017,CPF Feedmill KnowledgeBase,16,锤片式粉碎机 HAMMER MILL,12/12/2017,CPF Feedmill KnowledgeBase,17,锤片式粉碎机HAMMER MILL,12/12/2017,CPF Feedmill KnowledgeBase,18,Hammer mills,Flake Breaker,锤片式粉碎机 Hammer mills,12/12/2017,CPF Feedmill KnowledgeBase,19,对辊式粉碎机ROLLER MILL,12/12/2017,CPF Feedmill KnowledgeBase,20,破碎机CRUMBLER,12/12/2017,CPF Feedmill KnowledgeBase,21,盘磨机 BURR MILL,12/12/2017,CPF Feedmill KnowledgeBase,22,Lump Buster,Half Nelson Crusher,齿式破碎机 Crushers,Dual Rotor Full Nelson Crusher,Lump Abrader,Full Nelson Crusher,12/12/2017,CPF Feedmill KnowledgeBase,23,Rubber Bale Granulator System,Particle-izer,破饼机 Granulators,12/12/2017,CPF Feedmill KnowledgeBase,24,切碎机 Shredders,棘爪式切碎机Pallet Shredder,高扭矩切碎机Hi-torque Shredder,12/12/2017,CPF Feedmill KnowledgeBase,25,粉碎的价值 Value of Grinding,粉碎的价值 = 粉碎的效用 (Advantages of Grinding) Value (Grinding) 粉碎成本 (Grinding Cost)粉碎的效用如下 Advantages of grinding process consist of;达到需要的细度 Reduce particle size as required控制原料的均匀度 Control size and shape of raw materials regularly提高原料外表的面积 Increase surface area of material增加容重 Increase Bulk Density达到该产出的产能 Get grinding capacity as required减少损耗因为原料的粉尘 Reduce loss from diffusion of raw materials减少其他掺杂 Prevent strange matter令客户满意 Make customers satisfaction,12/12/2017,CPF Feedmill KnowledgeBase,26,粉碎的价值 = 粉碎的效用 (Advantages of Grinding) Value (Grinding) 粉碎成本 (Grinding Cost)粉碎成本如下 / Grinding process costs consist of;厂房的投资(折旧) / Building cost (Devaluation cost, Maintenance cost)设备的投资 (折旧,零配件, 物料消耗:锤片,筛网,除尘器) Machinery cost (Devaluation cost, Spare parts cost, Consumptive parts : Hammer beater, Screen, Bag filter)人工费 Labor cost (Operator cost, Maintenance cost)电费 Energy cost (Electrical cost)其他费用(检验费) Etc., (QC accessories cost),粉碎的价值 Value of Grinding,12/12/2017,CPF Feedmill KnowledgeBase,27,锤片式粉碎机的工作流程HAMMER MILL PROCESS,12/12/2017,CPF Feedmill KnowledgeBase,28,初始破碎区Primary Destruction Zone,加速区Acceleration Zone,全速区Full Hammer Tip Speed Zone,接触点Contact Point,重磨区Regrind Chamber“,下料导向板“ Flow Director“,锤片式粉碎机的工作原理HAMMER MILL PRINCIPLE,12/12/2017,CPF Feedmill KnowledgeBase,29,工作原理Operational Principles,原料送入粉碎室后,由于锤片速度高于原料速度,锤片和原料之间发生撞击, 随后原料再受到耐磨板的撞击。接着，锤片端部还载着原料使之受到静止筛网的摩擦。小于筛网孔的破碎原料颗粒在除尘系统的帮助下便穿出筛孔,除尘系统同时也起到避免堵塞筛孔的作用。留下来的原料速度不断增加直到等于锤片速度，在此期间撞击一直进行,但由于锤片与原料速度差的变化，撞击作用不断降低。 When material fed into the grinding chamber , beaters are higher speed than material then impact between beater and material and material is brought to be impacted by wear plate. Except that ,end of beater carry material to abrade with still screens. Broken material that are smaller than screen hole pushed out and sucked by aspiration system that prevent screen clogged ,too. Remaining material increased speed until equal to beater during that impact happen all the time but decrease continuously depending on difference speed between beater and material.,12/12/2017,CPF Feedmill KnowledgeBase,30,有些锤片粉碎机具有阻止原料运动的装置,增加锤片与原料之间的速度差，从而使原料受到重复冲击。 当其余原料通过锤片粉碎机的上部时，原料受到送入原料阻止而接受重复冲击。如果锤片与筛片筛孔仍然尖锐，就会出现小小的剪切效应。 Some hammer mills have devices for obstruct material movement that effect to increase different speed between beaters and material then impact occurred again. When remaining material pass the upper part of hammer mill ,will be obstructed by fed material then the impact cycle occurred again. If beaters and screen holes still sharp , shear force will a little bit occure.,工作原理Operational Principles,12/12/2017,CPF Feedmill KnowledgeBase,31,全筛式和部分筛式锤片粉碎机Full-circle & Half-circle Hammer mill,12/12/2017,CPF Feedmill KnowledgeBase,32,产能 Productivity （Ton/Hr）电机的功率 Motor power （KW/HP）每吨电耗 Electricity consumption（Kwh/Ton）筛网的开孔率 Opening area （%）粉碎机下面的缓冲斗 Hopper under HM风机 Blower吸尘布袋 Dust collecting bag,锤片粉碎机的计算CALCULATION OF HAMMER MILL,12/12/2017,CPF Feedmill KnowledgeBase,33,物料 Product %H2O t/m3 JKW豆粕 Soya extraction meal 12 0.6 70花生粕 Peanut extraction meal 12 0.6 70椰子粕 Coconut extraction meal 12 0.6 70美国玉米 Corn US 12 0.7 55小麦 Wheat 14 0.7 40大麦 Barley 12 0.7 27燕麦 Oats 12 0.7 14碎米 Rice 12 0.7 49黑麦 Rye 14 0.7 16次粉 Wheat bran, low in flour 13 0.25 12麦糠 Wheat bran, fine 13 0.3 33木薯粒 Manioc, tapioca pellets 10 0.6 85高粱 Sorghum, Milo 11 0.7 55 干草料 Dried forage 12 0.3 9肉粉 Meat meal 8 0.6 50秘鲁鱼粉 Fish meal, Peru 8 0.65 1,物料粉碎性能指标：JKW-系数Grindability of product : JKW-Factor,上表中根据不同的物料、水分和容重，在筛片开孔率40%、锤片端部线速度90 m/s 时，给出了不同的JKW参考值Table with JKW-values for different products, related moisture content and bulk density, at an open screen area of 40%, and a hammer tip speed of 90 m/s,12/12/2017,CPF Feedmill KnowledgeBase,34,Pre grinding system（先粉碎系统）m = 产量 Throughput in kg/hP = 马达功率 Motor load in kWW = 电耗 Spec. power consumption in kWh/t= 筛网工作孔径 Diameter of screen perforation in mmJKW = JKW系数 Grinding factor of product,m = P JKW = kg/h,P =,m,JKW,= kW,w =,1000,JKW ,= kWh/t,JKW =,m,P,= factor,例（ Example ）:马达功率 Motor load = 75 kW, 筛网孔径 Screen = 3 mm物料 Product US玉米 (US-corn),m = . . . = .kg/h,锤片粉碎机的计算CALCULATION OF HAMMER MILLS,12/12/2017,CPF Feedmill KnowledgeBase,35,后粉碎系统（ Post grinding system ）m = 产量（ Throughput ）in kg/hP = 马达功率（ Motor load ） in kWw = 电耗（ spec. power consumption ）in kWh/t = 筛网工作孔径in mm （ diameter of screen perforation ）JKW = JKW系数（ Grinding factor of product ）x = 物料百分率（ Proportion of product ） in %,例（ Example ）: 产量（ Throughput ） 10 t/h, 筛片孔径（ screen ） 3mm 物料（ Product ） 50% US-玉米（US-corn ) 30% 大麦 （ Barley ）, 20% 燕麦 （ Oat ）,.,.,+,+,P =,100 .,= kW,.,锤片粉碎机的计算CALCULATION OF HAMMER MILLS,12/12/2017,CPF Feedmill KnowledgeBase,36,筛网面积/电机功率比Screen Area per kW,通用 0.008 0.016 m2 / kW Ordinary use谷类颗粒原料 0.010 0.012 m2 / kW for cereal seed粉粘性高的原料 0.008 0.016 m2 / kW Well-gelatinized material使用小孔径的筛网 必须用更大的m2 / kW For Small hold : must use more m2 / kW不能用筛网的开孔面积/电机 功率比低于 0.003 m2 / kWCan not use screener that the ratio of opening area and horse power of motor less than 0.003 m2 / kW,12/12/2017,CPF Feedmill KnowledgeBase,37,筛网面积/电机功率比Screen Area & Kw,在粉碎玉米时怎样计算电机马达 (How to calculate the horse power of motor)30 x 54 粉碎机 筛网面积 2.9 m2(30 x 54 Hammer mill, Screen opening area)因为原料是玉米 选用筛网面积为 0.011 m2/ kW(Because raw material is corn, choose the opening area as)所以选用电机马达 (So use the motor) = 2.9 / 0.011 = 263 Kw (max)如果选用电机 (If select the motor) 250 Kw同时用筛网 (Screen hole) 3 mm 有 41 %的开孔率 (Opening area)等于开孔面积比电机kW = (2.9)(0.41)/250 (Ratio of opening area and motor horse power) = 0.005 m2/ kW如果选用筛网 (Screen hole) 1.5 mm 有 28 %的开孔率 (Opening area)等于开孔面积比电机kW = (2.9)(0.28) / 250 (Ratio of opening area and motor horse power) = 0.003 m2/ kW,12/12/2017,CPF Feedmill KnowledgeBase,38,= 90.7 * d2 t2,筛片开孔率Open Screen Area,12/12/2017,CPF Feedmill KnowledgeBase,39,长孔筛 Slot Screen,筛片面积 (Area) = 4,159.2孔数 (No. of hole) = 30 x 76.6孔面积 (Hole area) = 2,298开孔率 (Opening area)= 55%,12/12/2017,CPF Feedmill KnowledgeBase,40,长孔筛VS 普通冲孔筛Slot Screen VS Perforate Screen,v1,v2,v1,v2,12/12/2017,CPF Feedmill KnowledgeBase,41,对传统锤片粉碎机 For conventional hammermills,风量 m3/分Air volume in m3/min,Screen area in dm2 （筛片面积dm2）,2,卸料斗体积Surge hopper volume in m3,Screen area in m2（筛片面积 m2）,2,锤片粉碎机阻力（Resistance of hammermill） = 12 - 15 mbar,吸尘器阻力（Resistance of filter） = 10 - 15 mbar,除尘器单位面积的风量（ Load of filter surface per m2 ） General Aspiration,dust filter surface 6 m3/min/m2 Minerals,grasmeal,manioc filter surface 4 m3/min/m2 Husks of oat & rice filter surface 3 m3/min/m2 Total seperator Pnuematic transport filter surface 4 m3/min/m2 Suction transport filter surface 4 m3/min/m2 Hammer mill filter surface 4 m3/min/m2 Pellet cooler filter surface 4 m3/min/m2,锤片粉碎机通风除尘系统HAMMERMILL ASPIRATION SYSTEM,=,=,12/12/2017,CPF Feedmill KnowledgeBase,42,风量计算的影响因数 Multiplier Factor for Aspiration Calculation,筛孔因数 Considered from screen hole diameter直径 Hole diameter 4.0 mm 乘 multiply with 0.9直径 Hole diameter 3.5 mm 乘 multiply with 0.95直径 Hole diameter 3.0 mm 乘 multiply with 1.0直径 Hole diameter 2.8 mm 乘 multiply with 1.05直径 Hole diameter 2.5 mm 乘 multiply with 1.1直径 Hole diameter 2.0 mm 乘 multiply with 1.15直径 Hole diameter 1.5 mm 乘 multiply with 1.2锤片线速度因数 Hammer Tip Speed线速度 Tip Speed 120 m/s 乘 multiply with 1.1线速度 Tip Speed 100 m/s 乘 multiply with 1.0线速度 Tip Speed 90 m/s 乘 multiply with 0.9原料容重因数 Bulk Density of Raw Material比重大于 Bulk Density more than 0.65 kg/l 乘 multiply with 1.0比重 Bulk Density range 0.55-0.65 kg/l 乘 multiply with 1.05比重 Bulk Density range 0.50-0.55 kg/l 乘 multiply with 1.1比重 Bulk Density range 0.40-0.50 kg/l 乘 multiply with 1.15比重 Bulk Density range 0.30-0.40 kg/ 乘 multiply with 1.2比重 Bulk Density range 0.25-0.30 kg/l 乘 multiply with 1.25比重 Bulk Density range 0.15-0.25 kg/l 乘 multiply with 1.3比重 Bulk Density range 0.10-0.15 kg/l 乘 multiply with 1.35,12/12/2017,CPF Feedmill KnowledgeBase,43,设计参数 Designed values for HAMMERMILL,12/12/2017,CPF Feedmill KnowledgeBase,44,主要部件 Important parts of Hammer mill,12/12/2017,CPF Feedmill KnowledgeBase,45,主要部件 Important part,12/12/2017,CPF Feedmill KnowledgeBase,46,主要部件 Important part,12/12/2017,CPF Feedmill KnowledgeBase,47,主要部件 Important part,12/12/2017,CPF Feedmill KnowledgeBase,48,用于调整锤筛间隙的轴孔Hole for adjust distance between Hammer and Screen,12/12/2017,CPF Feedmill KnowledgeBase,49,粗磨时，锤片安装轴孔远离筛片Coarse position is further from screen,细磨时,锤片安装轴孔靠近筛片Fine position is closer toscreen,12/12/2017,CPF Feedmill KnowledgeBase,50,锤片 Hammer Beater,12/12/2017,CPF Feedmill KnowledgeBase,51,锤片的磨损分析 Worn out Hammer Beater,min. 5 mm,10-15 mm,12/12/2017,CPF Feedmill KnowledgeBase,52,锤片的磨损分析Worn out Hammer Beater,每运转 8-12 hrs 或初次使用粉碎机时, 应调换转动方向，以获得锤片的均匀磨损，减少机器振动以及获得均匀尺寸。 Should reverse rotating direction of beater every 8-12 hrs,or when first started Hammermill for beater evenly worn out, reduce vibration of Hammerrmill and product evenly size,12/12/2017,CPF Feedmill KnowledgeBase,53,锤片的磨损分析 Worn out Hammer Beater,12/12/2017,CPF Feedmill KnowledgeBase,54,更换锤片的经济曲线 Hammer Replacement Economics,0,.,00,0,.,05,0,.,10,0,.,15,0,.,20,0,.,25,0,.,30,0,.,35,0,.,40,0,.,45,6,12,18,24,30,36,42,48,54,60,Tons x,1000,$/Ton,锤片的吨使用价Hammers,磨机生产吨电费Electrical,合计Total,12/12/2017,CPF Feedmill KnowledgeBase,55,锤片轴安装示意图Beater Pattern,12/12/2017,CPF Feedmill KnowledgeBase,56,冲孔筛片 Perforate Screen,Round edge,Sharp edge,每次打开锤片粉碎机时，应将粉碎筛片掉转180. 因为筛片上面比下面要受到更多的冲击，磨损更大。Should turn the screen 180 every time you open the Hammermill. Because of the upper is more impacted and worn out than the lower.,Round edge,Sharp edge,筛孔将被堵塞Screen will be clogged,钝边,锐边,钝边,锐边,12/12/2017,CPF Feedmill KnowledgeBase,57,长孔筛片 Slot Screen,用于增加原料颗粒尺寸Used to increase particle size,12/12/2017,CPF Feedmill KnowledgeBase,58,更换筛片的经济曲线 Screen Replacement Economics,0,0,.,05,0,.,1,0,.,15,0,.,2,0,.,25,0,.,3,0,.,35,0