How to improve the material utilization rate of briquetting machine?

In today’s increasingly tight resources, improving the material utilization rate of industrial equipment has become an important means for enterprises to reduce costs and enhance competitiveness. As a kind of equipment widely used in metallurgy, building materials, chemical industry and other industries, the material utilization rate of the briquetting machine is directly related to the production efficiency and economic benefits of the enterprise. This article will explore how to effectively improve the material utilization rate of the ball press through a series of measures, in order to provide a reference for related industries.

Material utilization rate of the briquetting machine

briquetting machine

1. Accurately control the moisture content of the material

The moisture content of the material is a key factor affecting the molding effect of the briquetting machine. If the moisture content is too low, the adhesion between the materials is insufficient, resulting in the fragile pellets after molding; if the moisture content is too high, the pellets will be too soft and lack strength. Therefore, it is very important to accurately control the moisture content of the material. This can be achieved by adjusting the amount of water added during the mixing process or pre-drying the material before pressing.

2. Reduce impurities in the material

Impurities not only affect the quality of the pellets, but may also damage the ball press. By removing impurities in the material by pre-screening or using methods such as magnetic separation, the purity of the material can be improved, thereby improving the material utilization rate of the ball press.

3. Reasonable use of additives

The use of additives can improve the molding performance of materials, but they need to be reasonably selected according to the characteristics of the materials and production requirements. The right amount of additives can improve the strength and molding rate of the pellets, but excessive use will increase costs and even affect the quality of the pellets.

4. Optimize the particle size of the material

The particle size of the material has a direct impact on the molding effect of the briquetting machine. Too large or too small particles will affect the molding effect of the material. Generally, the particle size of the material should be controlled between 80 and 200 meshes to ensure uniform gaps between material particles and improve molding quality.

5. Improve the purity of the material

The higher the purity of the material, the better its molding effect. High-purity materials can reduce the impact of impurities on the molding effect, improve the strength and durability of the pellets, and thus improve the material utilization rate of the ball press.

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More detailed information about briquetting machine material utilization can be found at: https://www.zymining.com/en/a/news/briquetting-machine-material-utilization-rate.html

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Detailed explanation of the design points of the pre-pressing spiral of the high-pressure briquetting machine

In the field of industrial production, especially for those industries that need to convert powdered materials into pellets with specific shapes and strengths, high-pressure briquetting machines play a vital role. As a key component in the briquetting machine, the design and performance of the pre-pressing screw directly affect the pretreatment effect of the material and the quality of the final pellets. This article will discuss in detail the design points of the pre-pressing screw of the high-pressure briquetting machine, aiming to provide reference and guidance for the technological progress and equipment upgrades of related industries.

Design of pre-pressing screw of high-pressure briquetting machine

high-pressure briquetting machine

1. Driving mode of pre-pressing screw

The driving mode of pre-pressing screw is the core of its design. Usually, the pre-pressing screw is driven by an AC variable frequency reduction motor, which can provide constant torque to ensure that the material is subjected to uniform and stable force during the pre-pressing process. Another advantage of the variable frequency motor is that the speed can be adjusted according to the material characteristics and production requirements, thereby achieving accurate control of the pre-pressure.

2. Material and wear resistance of pre-pressing screw

The material selection of the pre-pressing screw is crucial because it directly affects the service life and maintenance cost of the equipment. Generally speaking, the pre-pressing screw shaft is made of high-strength alloy steel to ensure its stability and durability under high pressure. The spiral blades are coated with wear-resistant materials, such as carbide or ceramic materials, to reduce wear and extend the service life of the equipment.

3. Pitch design of pre-pressing spiral

The pitch design has an important influence on the working efficiency of the pre-pressing spiral and the fluidity of the material. Reasonable pitch design can ensure the continuous flow of materials during the pre-pressing process to avoid blockage and accumulation. The cylindrical variable pitch design is a common choice for pre-pressing spirals, which can provide gradually increasing pressure during the pre-pressing process to adapt to the characteristics of different materials.

high-pressure briquetting machine

4. Sealing performance of pre-pressing spiral

The sealing performance between the pre-pressing spiral and the roller is crucial to maintaining the stability of the internal environment of the briquetting machine. Good sealing can prevent material leakage and the entry of external impurities, thereby protecting the roller and extending the service life of the equipment. The stepped labyrinth seal is a commonly used sealing method, which realizes the effective sealing of the gap between the pre-pressing spiral and the roller through the cooperation of multiple sealing rings.

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For more detailed information on the design of the high pressure press preloading spiral, please click here: https://www.zymining.com/en/a/news/key-points-for-designing-the-pre-pressing-screw-of-high-pressure-briquetting-machine.html

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Introduction to High Pressure Roller Grinding Machine Drive System

The drive system of a high-pressure grinding roller (HPGR) is a crucial component that powers the rollers to perform efficient grinding under high pressure, a process commonly used in mining, cement, and aggregate industries. This system is responsible for providing the necessary torque and controlling the speed and load to optimize the grinding process.

The main aspects of an HPGR drive system

High-pressure grinding roller

1. Drive Types

Single Motor Drive: A single motor powers both rollers, typically through a gearbox and coupling arrangement. This setup can be simpler but may require a more complex transmission system to ensure synchronized roller rotation.

Dual Motor Drive: Each roller has its own motor, providing more control and flexibility. Dual motor drives are preferred in large-capacity or high-torque applications because they ensure that both rollers can operate independently while maintaining synchronized movement.

Hydraulic Drive: In some designs, hydraulic systems are used to drive the rollers. Hydraulic drives provide high torque and smooth control, which can be advantageous for handling varying material loads and ensuring even pressure distribution.

2. Control System

Variable Frequency Drive (VFD): VFDs are used to control the speed of the motors, allowing operators to adjust the roller speed based on the feed material characteristics and required grinding pressure. This flexibility is critical for optimizing efficiency and reducing wear on the rollers.

Load-Sensing System: A load-sensing mechanism monitors the pressure exerted on the rollers. The system adjusts the torque and speed accordingly to maintain consistent grinding pressure, which helps to optimize throughput and protect the rollers from overloads.

PLC and Automation: Many HPGR systems use programmable logic controllers (PLCs) with automation capabilities to monitor and adjust parameters in real-time. This helps to maintain a stable grinding process, reduce energy consumption, and improve the lifespan of the equipment.

3. Torque Control and Distribution

HPGR drive systems are designed to generate high torque to withstand the high-pressure grinding process. Torque control ensures even distribution of pressure across the roller width, preventing uneven wear on the rollers.

Dual motor drives often use torque distribution controls to synchronize the rotation of both rollers, balancing the load and optimizing material throughput.

High-pressure grinding roller

4. Gearbox and Couplings

Gearboxes in HPGR systems are robust and designed to handle high loads. Planetary gearboxes or helical gear systems are commonly used due to their high efficiency and torque-handling capabilities.

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For more detailed information about the transmission system of high pressure grinding roll, please click to visit: https://www.zymining.com/en/a/news/high-pressure-roller-grinding-machine-drive-system.html

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What are the safe operating procedures for compound crushers?

Safe operating procedures for compound crushers are essential for minimizing hazards and ensuring efficient, trouble-free operation. Compound crushers combine impact and compression crushing for breaking down materials, so here’s a guide on safe practices:

Safety operating procedures for compound crusher

compound crushers

1. Pre-Operational Checks

Inspect for damage: Before starting, check for any visible damage or wear on the crusher, including the feed hopper, crushing chamber, belts, and motor.

Ensure proper lubrication: Check lubrication points and oil levels to ensure all moving parts have adequate lubrication to avoid overheating and wear.

Clear the area: Ensure no unauthorized personnel are near the crusher during operation, as moving parts can be hazardous.

2. Starting the Crusher

Start in sequence: Begin by starting the ancillary equipment (conveyors, screens) before powering the crusher.

Observe for abnormalities: Listen for unusual noises or vibrations during startup. If you notice anything abnormal, stop the machine immediately for inspection.

Monitor feed size: Only feed materials within the crusher’s designed size limit to avoid blockages and damage.

3. Feeding Material

Uniform feed rate: Feed materials steadily and uniformly to prevent blockages and overloading, which can cause strain on the crusher components.

Avoid foreign objects: Ensure no metal or uncrushable objects enter the crusher, as these can cause severe damage to the machinery.

Avoid overfeeding: Overloading the crusher can lead to jams, overheating, or mechanical failure, so maintain a balanced feed.

4. During Operation

Regular monitoring: Check for abnormal sounds, vibrations, or excessive temperature changes in bearings and motors.

Adjust settings as needed: Some compound crushers allow adjustment of crushing speed or gap; make sure these settings are within the manufacturer’s recommendations.

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For more detailed information on the safe operation procedures of compound crusher, please click to visit: https://www.zymining.com/en/a/news/safety-operating-procedures-for-compound-crusher.html

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How to properly maintain the vibrating feeder

Proper maintenance of a vibrating feeder ensures optimal performance, prolongs the equipment’s life, and minimizes downtime. Vibrating feeders are essential for moving materials smoothly and consistently, so here’s a guide to effective maintenance practices:

Vibrating feeder maintenance

HSV feeder

1. Regular Inspections

Daily visual checks: Inspect for loose bolts, excessive wear, or cracks in the frame and support springs. Look for any signs of material buildup on the feeder pan that could impact vibration.

Check for abnormal vibrations: Listen for unusual sounds or vibrations that could indicate mechanical problems or unbalanced loads.

Inspect drive motor and belts: Check the drive motor and belts for signs of wear or alignment issues, as these can impact the feeder’s efficiency.

2. Lubricate Moving Parts

Follow lubrication schedule: Lubricate bearings, drive shafts, and any other moving parts according to the manufacturer’s guidelines. Over-lubrication or under-lubrication can cause mechanical issues.

Use recommended lubricants: Ensure you’re using the correct type and grade of lubricant for each component, as specified in the equipment manual.

3. Check and Adjust the Feeder’s Settings

Ensure proper vibration amplitude: Monitor and adjust the feeder’s amplitude settings if necessary to match the application requirements and material characteristics.

Calibrate the stroke: Regularly check and calibrate the stroke (the distance the feeder moves per cycle) to ensure it meets the required specifications.

Control feed rate: Maintain a steady and appropriate feed rate to prevent excessive wear and tear on the feeder pan and reduce potential overloads.

4. Inspect the Springs and Support Structure

Check spring integrity: Inspect the feeder springs for signs of fatigue or cracking, as damaged springs can reduce vibration efficiency and cause uneven feeding.

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For more detailed information on vibrating feeder maintenance, please click here: https://www.hsd-industry.com/news/vibrating-feeder-maintenance/

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Complete List of Vibrating Screen Models

Vibrating screens are used in a wide range of industries, including mining, aggregate, recycling, food processing, and pharmaceuticals, to separate materials by particle size. The screen models vary in design, size, and type based on their application. Below is a comprehensive list of the main types of vibrating screens, each with unique features:

1. Circular Vibrating Screens

Single Deck Circular Vibrating Screen: Has one layer of screen and is suitable for simple separation tasks.

Double Deck Circular Vibrating Screen: Has two layers of screen, allowing for multiple material separation stages.

Triple Deck Circular Vibrating Screen: Offers three layers of screen, enabling finer gradation.

Heavy-Duty Circular Vibrating Screen: Designed for large-scale and high-capacity applications, especially in mining.

2. Linear Vibrating Screens

Single Deck Linear Vibrating Screen: Single-layer, used for applications that need linear motion for simple material separation.

Double Deck Linear Vibrating Screen: Two layers of screens for finer separation.

Triple Deck Linear Vibrating Screen: Three layers, suitable for more detailed gradation.

Heavy-Duty Linear Vibrating Screen: Built for heavy-duty applications in mining and aggregates, with higher load capacities.

Arc Vibrating Screen

3. Elliptical Vibrating Screens

Elliptical Single Deck Screen: Uses an elliptical motion, often for sticky or damp materials.

Elliptical Double Deck Screen: Two decks, typically for more complex separation processes.

Heavy-Duty Elliptical Vibrating Screen: Designed for tougher applications where an elliptical motion helps prevent clogging.

4. Dewatering Screens

Single Deck Dewatering Screen: Used to remove moisture from materials, often in mining or sand processing.

Double Deck Dewatering Screen: Features two decks for more efficient dewatering.

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For more detailed information about the vibrating screen models, please click here: https://www.hsd-industry.com/news/vibrating-screens-models/

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How to select vibrating screen

As a widely used equipment for solid-liquid separation, vibrating screen plays a vital role in the screening of particulate materials in different fields. In the process of selecting a vibrating screen, multiple factors need to be considered to ensure that the equipment suitable for actual needs is selected.

How to choose a vibrating screen

Cooperation Customer

1. Screening material characteristics

The working performance of the vibrating screen is directly affected by the characteristics of the screening material. Consider the particle size distribution of the material and understand the size range of the particles in the material to select the appropriate mesh size. Humidity and viscosity are also important considerations. For materials with high viscosity, it is necessary to select a vibrating screen with an anti-stick coating to avoid blockage and reduce efficiency.

2. Screening capacity

Different industries have different requirements for the screening capacity and processing capacity of vibrating screens. According to actual production needs, it is necessary to clarify the required screening capacity, that is, the number of materials required to be screened per unit time, and the overall processing capacity. This helps to select a vibrating screen of appropriate specifications to ensure that it can meet production requirements.

3. Mesh size

The mesh size of the vibrating screen is directly related to the screening effect. When selecting, it is necessary to select the appropriate mesh size according to the particle size distribution of the material. Too large a mesh may lead to ineffective screening, while too small a mesh may cause blockage and affect production efficiency. Reasonable selection of mesh size can effectively improve screening efficiency.

4. Structural material

The structure and material of the vibrating screen are directly related to the service life and stability of the equipment. A vibrating screen with a sturdy structure can usually better resist vibration and impact and improve the stability of the equipment. Choosing wear-resistant and corrosion-resistant materials can extend the service life of the vibrating screen and reduce maintenance costs.

Double banana sieve

5. Operation and maintenance

The convenience of operation and maintenance of the vibrating screen is directly related to the continuity and stability of the production process. A simple and easy-to-understand operating interface and convenient maintenance methods can reduce the difficulty of operation for personnel, reduce human errors, and improve production efficiency. The easy-to-maintain vibrating screen design can reduce equipment downtime and further improve production efficiency.

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For more detailed information about vibrating screening type, please click here: https://www.hsd-industry.com/news/vibrating-screen-selection/

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What are the screening methods of linear vibrating screen?

Linear vibrating screen is very suitable for assembly line operation, and it has the advantages of low energy consumption, high output, and automatic discharge, which makes it less common in the mining industry. The general screening process is that the material enters the feed port of the equipment evenly from the feeder, and the screen produces the screened material and the screened material through the screen, which are discharged from their respective outlets. The linear vibrating screen also has different screening methods.

Linear vibrating screen screening method

Single layer horizontal sieve

1. Linear vibrating screen dry screening

The so-called linear vibrating screen dry screening, as the name suggests, is to calculate the sum of the screen residue and the screen bottom inventory of each screen and the difference between the total dry mass of the sample before screening, as the loss during screening, and calculate the loss rate, put a certain weight of powder sample in the screen, with the help of mechanical vibration or manual patting to make the fine powder pass through the screen until the screening is complete, and the screen residue of the powder sample is calculated according to the weight of the screen residue and the weight of the sample. When measuring the particle size distribution, dry screening is generally used.

2. Linear vibrating screen overlapping method screening

Overlapping method screening means that in the process from coarse screen to linear vibrating screen, the screen surface of the vibrating screen overlaps, the screen hole of the upper screen surface is larger, and the subsequent layers gradually decrease, because there are gaps on both sides of the linear screen frame, which may lead to screening accuracy. This screening method is simplified and suitable for the processing of a large number of materials

3. Linear vibrating screen wet screening

Linear vibrating screen wet screening is to place a certain weight of powder sample in the screen, and after being washed for a certain period of time by a suitable dispersed water flow (with a certain water pressure), the screening is complete. The wet screening method is to calculate the screen residue of the powder sample according to the weight of the screen residue and the weight of the sample. If the sample contains more water and the particles are more condensed, wet screening should be used (with higher accuracy than dry screening), especially for materials with finer particles. If it is allowed to mix with water, try to use the wet method. Because the wet method can prevent very fine particles from adhering to the screen holes and blocking the screen holes. In addition, the wet method is not affected by the material temperature and atmospheric humidity, and the wet method can also improve the operating conditions. Therefore, both the wet method and the dry method have been listed as standard methods and acted in parallel as a method for determining the fineness of cement and raw materials.

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For more detailed information about linear vibrating screen screening methods, please click here: https://www.hsd-industry.com/news/linear-vibrating-screen-screening-method/

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How to design a vibrating feeder?

A vibrating feeder is a piece of industrial equipment designed to move or feed materials, usually bulk or granular materials, from one location to another in a controlled manner. It utilizes vibratory motion to transport materials across a surface or within a channel.

Designing a vibrating feeder requires consideration of several factors, including material characteristics, feeder capacity, operational requirements, and more. Here are some key design principles and steps:

Vibrating feeder design

vibrating feeder

Understand material characteristics: Material particle size, density, moisture content, and flowability affect feeder capacity and design parameters. These characteristics are critical in selecting the appropriate feeder type and size.

Determine operational requirements: The desired feed rate of the feeder needs to be considered during the design process. The feeder should be designed to ensure consistent and controlled flow of material to meet the needs of downstream processes.

Choose the appropriate drive type: Vibrating feeders can be electromagnetically driven or electromagnetically mechanically driven. The drive is the primary element in controlling vibration and is isolated from the supporting structure by appropriate isolation springs.

vibrating feeder

Design the trough: The trough is the only part that comes in contact with the conveyed material and can be made of a variety of materials and in almost any shape and size to accommodate a variety of processes where the material is in motion.

Consider vibration parameters: The vibration parameters of a vibrating feeder, such as amplitude, frequency, and vibration direction, need to be carefully designed to ensure proper material flow and prevent clogging or overflow.

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More detailed information about vibrating feeder design can be found at: https://www.zexciter.com/en/a/news/vibrating-feeder-design.html

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What are the faults of welding rotator and how to solve them

Welding rotators are essential tools in the welding process, especially for cylindrical components like pipes and tanks. They help rotate the workpiece at a controlled speed, allowing a more precise weld. However, they can experience several faults or issues over time due to mechanical wear, electrical problems, or improper usage.

Common faults and solutions of welding rotators

welding rotators

Rotation mechanism failure: If there is a problem with the rotation mechanism of the welding roller frame, it may be due to wear or damage of the rollers, gears or chains.

The solution is to check and replace the worn parts to ensure that the rotation mechanism works properly.

Failure of the clamping mechanism: If the clamping mechanism cannot firmly hold the workpiece, it may be due to wear or damage of the clamping device.

The solution is to check the clamping device and make necessary repairs or replacements.

Unstable rotation speed: If the rotation speed cannot be adjusted or is unstable, it may be due to problems with the control panel or inverter.

The solution is to check the settings of the control panel and inverter and make necessary adjustments or repairs.

Inaccurate positioning of the workpiece: If the welding roller frame cannot accurately position the workpiece, it may be due to problems with the level or parallelism of the roller frame.

welding rotators

The solution is to readjust the position of the roller frame to ensure that its level and parallelism meet the requirements.

Electrical failure: If there is a problem with the electrical system of the welding roller frame, it may be due to damaged cables, poor contact or faulty electrical components.

The solution is to check the electrical system, including cables, connections and control panels, and make necessary repairs or replacements.

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For more detailed information on common faults and solutions of welding roller frames, please click to visit: https://www.bota-weld.com/en/a/news/common-faults-and-solutions-of-welding-rotator.html

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