许辉明-混合技术培训.ppt

2019/6/27,1,混合技术 MIXING TECHNOLOGY,配料 搅拌 Proportioning - Homogenizing,2019/6/27,2,混合技术 Mixing Technology, 混合的重要性 Importance of mixing 混合定义 Definition of mixing 配料过程 Proportioning Process 配料时间及精度 Time and accuracy 原料配料指标 Raw material proportional indicator 预防性维修 Preventive maintenance 混合过程 Homogenizing Process 分批混合 Batch wise Mixing 混合均匀度 Precision of mixing 连续混合 Continuous Mixing 混合循环表 Mixing Cycle Diagram 计算方法 Calculation,6/27/2019,3,混合的价值 Value of mixing,混合的效用 ;如下 Advantages of mixing consist of; 达到配方要求的原料配比 Get raw material proportion as required formula 每批的原料比例相对稳定 Regular raw materials proportion in sample 满足均匀度 Homogeneous 使原料充分吸收添加的液体并避免成块 Raw material able to absorb adding liquid and do not agglomerate. 在规定的时间内获得稳定的优质产品 Get regular quality product within assign time 去处杂质,避免药物残留 Prevent strange matter and remainder in meat 稳定的外观质量令客户满意 Regular physical quality that make customer satisfaction,6/27/2019,4,混合的价值 Value of mixing,混合成本包括 Mixing costs consists 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) Machinery cost (Devaluation cost, Spare parts cost, Consumptive parts) 劳务费 Labor cost (Operator cost, Maintenance cost) 电费,燃料费 Energy cost (Electrical cost, Steam produced cost) 其他费用(检验费) Etc., (QC accessories cost),2019/6/27,5,在足够的时间和搅动作用下,原料在混合机内运动使各种原料混合均匀. 每种原料的每一个部分都分散在整个混合物中,所以在每一处取样都能得到相同的原料成分。 The movement of raw material inside mixer causes homogeneity when there are sufficient time and turmoil. Each part or each type of raw material will scatter indiscriminately within the whole mass of mixture, in order, every taken samples has same raw material proportionally.,混合定义 Definition of mixing,2019/6/27,6,配料过程 Weighing Process,目标 (Target) 配料时间 Time per batch 配料准确度和精密度 Accuracy and precision,2019/6/27,7,称量时间 Time per batch,配料时间取决于： Time per batch depends on : 1. 合理选用每种原料所进的配料仓,以便原料能按配方量正确进入配料秤 Selection of raw material loading to bin which has an ability to discharge to scale in proper with the amount of weight scale. 两台秤的容量尽量接近 Nearly same amount between two scales 3. 配料绞龙的能力 Ability of conveyor 4. 秤的准确度和精密度 Accuracy and precision of scale 5. 设定的参数 (零位, 落差量) Parameters setting (; zero ,suspend) 6. 放料时间 Ability of discharging from scale,2019/6/27,8,准确度和精密度 Accuracy and Precision,准确度高 精密度高 Good Accuracy - Good Precision,准确度高 精密度低 Good Accuracy - Poor Precision,准确度低 精密度高 Poor Accuracy - Good Precision,准确度低 精密度低 Poor Accuracy - Poor Precision,2019/6/27,9,准确度和精密度高 Accuracy and Precision,取决于： Accuracy and Precision 配料绞龙的精度 Feeder Accuracy 配料秤的精度 Scale Accuracy 称量仪表的精度 Weight Indicator Accuracy,2019/6/27,10,喂料绞龙的精度 Feeder Accuracy,喂料绞龙的精度取决于： Feeder Accuracy depends on : 喂料绞龙设计 (高转速的小绞龙比低转速的大绞龙精度更好) Screw feeder design - small feeder (high revolution) is more accurate than large feeder (low revolution) 2. 喂料绞龙的使用 Screw feeder application 3. 控制系统的设计 Electrical control design 4. 机械惯性 (机械传动) Mechanical inertia (Power Transmission) 5. 电器惯性 (动作时间) Electrical inertia (Decelerate Time) 6. 料流的连续性 Continuities of conveying,2019/6/27,11,标准的配料过程 Normal Dosing,参数 P1 快进/慢进转换点 Switch fast/slow kg P2 慢进料停止点 pre cut-off weight kg r1 负偏差 (-) tolerance (-) kg r2 正偏差 (+) tolerance (+) kg t1 慢进料时间 switch time fast/slow t2 目标称量延迟时间 target dosing time slow t3 称量后落差时间 settling after dosing t4 最大称量时间 max. dosing time v2 快加料速度 dosing speed fast v1 慢加料速度 dosing speed slow W1 慢加料重量 switch fast/slow kg W2 落差重量 pre cut-off weight kg,2019/6/27,KNOWLEDGEBASE DEVELOPMENT AGRO FEEDMILL BUSINESS,12,配料仓参数 Bin parameter - 正偏差 positive tolerance su - 负偏差 negative tolerance su - 慢加料点 Fine dosing section su - 落差点 Pre cut-off point su - 重新称量脉冲时间（秒） Redosing pulse length (sec) - 快加料比例 Fast dosing % - 慢加料比例 Fine dosing %,配料秤参数 Scale parameter - 零偏差 (Zero tolerance) 数值 (su) - 配料时间 (Dosing supervision time) 秒(sec) - 放料时间 (Emptying supervision time) 秒(sec) - 暂停快/慢车 (Pause fast / slow) 秒(sec) - 稳定时间 (Steadying time) 秒(sec) - 清理残留时间(Residual emptying time) 秒sec) - 启动延迟时间 (Start delay) 秒(sec),称量单位 ( 数值 ) = Scale unit ( su ),配料秤容量(kg) (Scale size in kg),交/直流转换器量程 (Resolution A/D converter),配料过程分析 Dosing Algorithm,2019/6/27,13,配料器通常安装在秤斗上面,距地面数米高，故接近较困难。 Dosing elements are usually installed above the scale hoppers and several meters above the ground. Therefore access to them is in most cases difficult.,对配料器的要求: Requirements to dosing elements:,配料器 Dosing Elements,2019/6/27,14,配料器 配料绞龙 Dosing Element : Screw feeder,2019/6/27,15,配料绞龙要点 Screw Feeder Key Points, 送料螺距/直径比 Pitch/Diameter Ratio For Conveying - 对轻的或普通原料，最大为2/3 (0.67)； Maximum 2/3 (0.67) for light or normal materials - 对重的或小量使用原料，最大为1/2 (0.50)； Maximum 1/2 (0.50) for heavy materials or materials used in small quantities 紧接进料口设置限料器(2倍螺距的长度)，使喂料更精确； Top shroud (2 flighting diameter length) just beyond bin outlet allow more accurate metering 限料器后面的单螺杆，容许配料绞龙低速运转，便于快速停止喂料,获得高精度。 Full pitch after shroud allows feeder to run below capacity for more accurate discharge cut-off 排料口前的双螺杆或1/2叶片， 减少排料时的浪涌,使排料平稳。 Double flighting or 1/2 bare flight before discharge reduces product surging and smooth-out delivery,2019/6/27,16,配料绞龙 Screw Feeder,2019/6/27,17,配料器 : 微量喂料绞龙 Dosing Element : Micro screw feeder,2019/6/27,18,配料器: 滑动插板 Dosing Element : Slide feeder,2019/6/27,19,配料器: 配料盘 Dosing Element : Bin discharge,2019/6/27,20,配料秤的精度 Scale Accuracy,配料秤的精度取决于： Scale Accuracy depends on : 秤斗形状设计 Design of scale shape 秤斗和传感器的安装 : 均衡和对称 Scale and load cell installation : center and symmetrical 传感器的安装和调整 : 受力均衡 Installation and adjustment of Load Cell : balance 传感器质量 Load Cell Resolution 传感器防止受干扰 Prevention of noise signal disturb to Load Cell 原料进秤口的设计 Design of raw material intake to scale 配料顺序 Sequence of weighing 校秤频率 Frequency of Scale Calibration,2019/6/27,21,进料口布置 Bin Spout Placement,2019/6/27,22,称重仪表的精度 Weight Indicator Accuracy,称重仪表的精度取决于： Weight Indicator Accuracy depends on : 根据传感器选择仪表的型号规格和信号 Selection of type, range and signal in related with Load Cell 仪表到传感器的距离不超过设计要求 Distance from Load Cell is not more than indicated range 防止不良信号干扰 Prevention of noise signal disturbance 仪表指示的转速和范围 Range and Revolution selection of Weight Indicator 参数设定 Parameters setting 与电脑连接方法 Communication with Computer Control 调试频率 Frequency of Weight Indicator Calibration 重量指示器 Weight Indicator,2019/6/27,23, 配料秤及配料器的精度 = 0.2 % 的额定配料量 Accuracy of Scale & Dosing Element = 0.2 % of Scale Capacity 营养容许偏差 = 每种成分的5.0 % Tolerance which Nutritionist Accept = 5.0 % per Component 例如 : 2 吨配料秤的最小称量值 ： Example : Minimum weight of 2 tons scale Calculation 配料秤有0.2 % 的误差， 所以 2000 kg 的秤的误差=2000 x 0.2/100=4 kg (表示在称 100 kg时， 秤可显示 100 + 4 kg 或者 96 kg 104 kg ) 可接受 5.0 % 误差 表示在称 100 kg 时 可以接收误差 100 + 5 kg 或者 95 kg 105 kg 内 accuracy 0.2 % of scale 2000 kg = 2000 x 0.2/100 = 4 kg (This means, at weight 100 kg , scale is possible to display between range 100 + 4 kg or 96 kg 104 kg ) tolerance 5.0 % means if the weight 100 kg is required, the acceptable variance at 100 + 5 kg or 95 kg 105 kg,配料秤保证精度的最小称量值 Minimum weight : Scale still maintain accuracy,2019/6/27,KNOWLEDGEBASE DEVELOPMENT AGRO FEEDMILL BUSINESS,24,所以可以使用的最小称量是 5 % 等于 4 kg 在 100 % 等于 (4 x 100)/5 = 80 kg ( 表示在称80 kg时，秤可显示 80 + 4 kg 表示有误差 5.0 % ) So, the minimum weight within range of tolerance is 5 % equal to 4 kg and 100 % equal to (4 x 100) / 5 = 80 kg (This means at 80 kg weight , scale is possible to display between range 80 + 4 kg , tolerance 5.0 % ) 计算可以使用的最小称量等于精确度(%) / 最大称量偏差（%） 以上计算方法是 0.2/5 of 2000 kg = 80 kg 如果称 40 kg + 4 kg时， 有误差 (4/40)x100 = 10 % Or minimum weight that scale still maintain accuracy is accuracy (%) / tolerance (%) of Scale Capacity From example can be calculated to : 0.2/5 of 2000 kg = 80 kg If display 40 kg + 4 kg so tolerance is equal to (4/40)x100 = 10 %,配料秤保证精度的最小称量值 Minimum weight : Scale still maintain accuracy,2019/6/27,25,维护保养 Scale Maintenance,2019/6/27,26,混合过程 Homogenizing Process,2019/6/27,27,选择混合系统所考虑的因素 Consideration of mixing system selection depends on:,精度与自动化程度要求 Requirements to accuracy and degree of automation. 原料与劳务工的可利用性 Availability of raw material and labours 建设规定与市场要求 Considerations of building constraints and market demands,通常混合系统有 2 种 Ordinary case, the mixing system can be considered by 2 types,连续混合 CONTINUOUS MIXING 容积式 Volumetric 重量式 Gravimetric,批次混合 BATCHWISE MIXING 前粉碎 Pre grinding 后粉碎 Post grinding,混合系统 Mixing System,2019/6/27,28,混合均匀度的意义？ What means homogeneity and mixing accuracy?,混合均匀度指示单一原料 在由其它原料组成的总体 成分中分布的程度。 The homogeneity or mixing accuracy of a mixture indicates how efficient the single ingredient is distributed among the totality of the other ingredients.,混合过程的要求 Mixing Requirement,下页继续 Continue next page,2019/6/27,29,由于散装固体结构所决定，不可能达到 100%的混合均匀度。 Due to structure of bulk solids, it is impossible to obtain a hundred percent homogeneity 因此混合均匀度以变异系数CV（%）表示 Therefore the homogeneity is expressed by the coefficient of variation CV %,根据欧洲标准， 混合均匀度应该达到 According to european standard a homogeneous mixture should have a CV of 5 %,混合过程的要求 Mixing Requirement,从上页 From previous page,2019/6/27,30,影响混合时间及均匀度 (%CV)因素 The factors influence Mixing Time and Mixing Homogeneity (%CV),混合机的形式 Mixer type 混合机的长度或者 Length or Height compared with diameter 高度和直径的比例 3. 转速 Revolution 4. 混合机部件的磨损和损坏 Wear and tear of mixer parts 5. 混合机内的清洁 Cleanness of inside Mixer 6. 混合料的数量 Amount of material inside mixer 7. 原料进混合机的位置 Location of material intake to mixer 8. 原料进料顺序和时间 Sequence and time of material filling 9. 液体喷射方式 Liquid spray 10. 原料特性 Characteristics of raw material,2019/6/27,31,混合机种类 Type of Mixer,1. 立式混合机 VERTICAL MIXER 混合时间长 (3-15分钟) Mixing time : long (3-15 minutes) 2. 滚筒式混合机 DRUM MIXER 混合时间3-10 分钟 Mixing time : medium (3-10 minutes) 3. 卧式混合机 HORIZONTAL MIXER 3.1 单轴双螺带 SINGLE SHAFT-DOUBLE RIBBON MIXER 混合时间短(3-5分钟) Mixing time : short (3-5 minutes) 3.2 双轴双螺带 DOUBLE SHAFT-DOUBLE RIBBON MIXER 混合时间短(2-3分钟) Mixing time : short (2-3 minutes) 3.3 单轴单桨叶 SINGLE SHAFT-SINGLE PADDLE MIXER 混合时间短(4-5分钟) Mixing time : short (4-5 minutes) 3.4 单轴双桨叶 SINGLE SHAFT-DOUBLE PADDLE MIXER 混合时间短(2-3分钟) Mixing time : short (2-3 minutes) 3.5 双轴双桨叶 DOUBLE SHAFT-SINGLE PADDLE MIXER 混合时间短(1-2分钟) Mixing time : short (1-2 minutes) 3.6 其他种混合机 Other type,2019/6/27,32,混合机种类 Type of Mixer,2019/6/27,33,立式混合机 Vertical Mixer,2019/6/27,34,单轴立式混合机 SINGLE SHAFT VERTICAL MIXER,2019/6/27,35,滚筒式混合机 Drum Mixer,2019/6/27,36,滚筒(箱型)混合机 Drum(Cube) Mixer,2019/6/27,37,单轴-双螺带混合机 Single Shaft -Double Ribbon Mixer,2019/6/27,38,改进型螺带 Improved Ribbon Design,2019/6/27,39,单轴 双螺带混合机 Single Shaft -Double Ribbon Mixer,2019/6/27,40,双轴 双螺带混合机 Double Shaft -Double Ribbon Mixer,2019/6/27,41,双轴-单螺带混合机 Double Shaft - Single Ribbon Mixer,2019/6/27,42,单轴-单桨叶混合机 Single Shaft - Single Paddle Mixer,2019/6/27,43,单轴-单桨叶混合机 Single Shaft -Single Paddle Mixer,2019/6/27,44,单轴-双桨叶混合机 Single Shaft - Double Paddle Mixer,2019/6/27,45,单轴-双桨叶混合机 Single Shaft -Double Paddle Mixer,2019/6/27,46,双轴 双桨叶混合机 Double Shaft -Double Paddle Mixer,2019/6/27,47,双轴 双桨叶混合机 Double Shaft -Double Paddle Mixer,2019/6/27,48,V 型混合机 V-shaped Mixer,2019/6/27,49,圆筒型混合机 Cylindrical Mixer,2019/6/27,50,4 叶混合机 4 Augers Mixer,2019/6/27,51,2019/6/27,52,原料在混合机内 的运动轨迹 Direction of material movement inside mixer,2019/6/27,53,原料在混合机内的运动轨迹 Direction of material movement inside mixer,2019/6/27,54,原料在混合机内的运动轨迹 Direction of material movement inside mixer,2019/6/27,55,原料在混合机内的运动轨迹 Direction of material movement inside mixer,2019/6/27,56,长度或者高度和直径比在1-3 *如果这比例接近1,混合时间会减少 Size of mixer should has Length or Height with diameter ratio between 1 - 3 * The more ratio approach 1 The less mixing time,混合机的长度或者高度和直径比 Length or Height compared with diameter,2019/6/27,57,混合机的长度或者高度和直径比 Length or Height compared with diameter,2019/6/27,58,混合机不同的转速 Revolution of Paddle-screw combination,2019/6/27,59,混合机部件磨损和损坏的影响 Wear and tear of mixer parts,2019/6/27,60,混合机部件磨损和损坏的影响 Wear and tear of mixer parts,2019/6/27,61,混合机内的清洁度的影响 Inside of Mixer Cleanness,2019/6/27,62,混合量的影响 Amount of material inside mixer,2019/6/27,63,混合量的影响 Amount of material inside mixer,2019/6/27,64,进料位置的影响 Position of material intake to mixer,2019/6/27,65,主原料 Major raw material 副原料包括预混料和矿物质 Minor raw material including premix and minerals 化学药品 Chemical substance 液体 Liquid,进料顺序 Sequence of material filling,2019/6/27,66,混合时间对均匀度的影响 Homogeneity in function of mixing time,2019/6/27,67,1. 液体的颗粒越细越好,以便喷成雾状 Size of liquid must be smallest that mean the liquid should be sprayed almost like mist 2. 液体必须充分喷到干的原料上 Liquid must touch with dry material thoroughly 2.1 喷嘴的安装: 沿混合机长度方向分布 Liquid spray nozzle installation : distribute along mixer length 2.2 喷嘴的位置: 不可喷到混合机内任何其他部件 Position of nozzle : not spray to any other parts inside mixer 液体喷射的时间和顺序 Time and sequence of Liquid spray,液体添加 Liquid spray,2019/6/27,68,液体添加 Liquid spray,2019/6/27,69,液体添加 Liquid spray,2019/6/27,70,喷嘴的位置 Position of nozzle,2019/6/27,71,喷嘴修正 Nozzle Modification,2019/6/27,72,1. 原料尺寸 Size of raw material 2. 原料形状 Shape of raw material 3. 原料比重 Density of raw material 4. 吸水性 Absorbability of moisture 5. 静电 Static electricity 6. 化学拉力 Chemical force 7. 流动性 Fluidizability,原料特性 Characteristics of raw material,2019/6/27,73,对产品的物理性能要求 Physical requirements to product properties,重要规则: As a rule of thumb: 粒度: Granulation: 各种原料的颗粒大小应在大约 3 mm 以内。 The particle size of the individual components should be in a range of approx. 3 mm. 堆放密度: Bulk density: 各种原料的堆放密度应在大约 0.5 kg/dm3。 The bulk density of the individual components should be in a range of approx. 0.5 kg/dm3,最有效的混合机也不能在每种原料粒度与密度变化较大时仍产生均匀的混合。 The most efficient mixer can not produce a homogeneous mixture if the components vary too much in granulation and bulk density.,原料特性 Characteristics of raw material,2019/6/27,74,残留量约为 混合机产能的 0.2 % (如：2000kg混合机有4kg ) Approx : 0.2 % of mixer capacity (e.g. 4kg in 2,000 kg mixer),取决于：Depending on: 混合物性质 多粘的 Nature of mixture stickiness 混合机内部件表面 生锈的，吸附大 Surface of mixer interior rust, build up 液体添加情况 多稠，吸附大 Function of liquid addition dripping, build up system 转子与机筒的间隙 磨损大 Clearance between rotor wear and trough 排料门开启时间 太短 Opening time of discharge flap too short 混合机后缓冲斗大小 太小 Size of dump hopper after mixer too small,混合机内的残留量 The amount of remaining after discharging,2019/6/27,75,改善办法: Remedy: 经常清理混合机 Clean mixer more frequently 检查液体添加系统 Check liquid addition system 重新调整桨叶位置 Readjust paddles 更换/焊牢螺带 Change / weld-up of spiral 重新调整排料时间 Readjust discharge time 增加缓冲斗容积 Adapt dump hopper size,注意: 对部分混合批次， 残留量也为 整个混合机产能的0.2 % Note: Also for partial batches the amount of residue is 0.2% of the full capacity of the mixer,混合机内的残留量 The amount of remaining after discharging,2019/6/27,76,例子: 2,000 kg 混合机 Example: 2,000 kg mixer 直径 1,500 mm Diameter 1,500 mm 长度 3,100 mm Length 3,100 mm,内部表面积 (Surface area inside approx) 18 m2 = 1,800 dm2 残留量 (Residue) 2,000 kg 的 0.2 % = 4 kg 原料密度 (At a bulk density of) 0.5 kg/dm3 = 8 dm3 8 dm3 在整个1,800 dm2表面上的分布 8 dm3 spread over the area of 1,800 dm2 = 残留料层厚 (Layer of dust) 0.0044 dm = 残留料层厚 (Layer of dust) 0.44 mm,混合机内的残留量 The amount of remaining after discharging,2019/6/27,77,螺带-转子 Spiral-rotor 能在整个进料口长度范围进料； Filling over the entire length of inlet possible 排料后残留量为0.2 %； Residue after discharge (Try mixing) 0.2 % 少量混合的最小值为额定量的60% Partial batches min. 60% of mixer capacity （转子轴应被覆盖）； (shaft of rotor must be covered). 不便于维修。 Difficult to maintain.,螺带式和桨叶式的比较 Comparison between Ribbon mixer and Paddle mixer,2019/6/27,78,桨叶-转子 Paddle-rotor 对原料改变小； Gentle treatment of the product 少量混合量可降低至20%; Partial batches down to 20 % possible 排料后残留量为 0.15 - 0.2 % Residue after discharge (try mixing) 0.15 - 0.2 % 桨叶可调整；. Adjustable paddles 维修保养方便； Easy maintenance. 仅能在转子轴长度的中间进料。 Filling only in middle third,螺带式和桨叶式的比较 Comparison between Ribbon mixer and Paddle mixer,2019/6/27,79,混合均匀度 Mixing Accuracy,2019/6/27,80,原料配比. proportioning of components - 配料秤精度 accuracy of scales - 配料器精度 accuracy of dosing elements 原料性能 Product properties - 颗粒尺寸 particle size - 颗粒形状 particle shape - 堆放密度 bulk density 原料颗粒的尺寸 Size of component - 占整个批次的% in % of the total batch 混合机型式 Type of mixer - 混合机的设计 depending on mixer design - 混合方式 depending on mixing tools 混合时间 Mixing time - 卧式混合机 horizontal mixers. - 立式混合机. vertical mixers 液体添加 Liquid addition - 结块情况 lump formation.,影响混合均匀度的因素 The mixing accuracy influences,2019/6/27,81,借助于混合均匀度试验检查混合精确度 Check of mixing accuracy by means of a homogeneity test., 在每一个样品中跟踪所有原料是非常困难和浪费时间的。 Tracing of all ingredients in each sample very difficult and time consuming 实际上在所有样本中仅标识一种物质，用以代表其它所有原料。 In practice only one substance is identified, in all samples, serving as a representative for all of the others.