MDR-5系列离心喷雾干燥机说明书.doc

MDR SeriesCentrifuge Spray Dryer产品说明书Operating ManualWUXI MODERN SPRAY DRYING EQUIPMENT Co.,ltdGeneral Introducing前 言本厂生产现代最新MDR系列离心喷雾干燥机和MDP系列喷雾造粒等干燥设备。并具有20多年干燥技术的专业技术骨干和技术人员。本厂设备新颖、并根据用户需要设计大、中、小各种现代干燥设备。本厂技术力量雄厚，设备先进，服务周到，用户至上，在干燥行业中以现代最新的设备面貌展现于国内外。高速离心喷雾干燥机是一种新型高效干燥工艺装备，它可以使溶液乳浊液、悬浮液、糊状液的物料，经过喷雾干燥成为干粉状、细中颗粒的制品。它干燥速度快、效率高、工序少、节省人力。特别对于热敏性的物料，可以保持物料的色、香、味。产品质量优良，干燥制品流动性好、溶解性好、纯度高、环境卫生好。有利于提高产量并获得良好产品质量、经济效益。在化工、轻工、建材、食品、林产化工、药物、生化、环保等行业有着广阔的前途。Modern Spray Drying design and manufacture advanced MDR series Centrifuge spray dryer and MDP series spray granulating dryer. Modern Spray Drying has professional spray drying technical engineer and technician who are specialist in spray drying for more than 20 years.This equipment can be used to dry materials in forms of solution ,emulsion,suspension and pasty.After spray drying, product is fine and dry powder. It has the advantage of fast drying speed,high drying efficient, less drying process,and labor saving.This equipment will keep color, flavor and taste of product.Final procduct will keep good flowability, good solubility , high purity. This equipment will finish spray drying and granulating process at the same time. Liquid will pass through mono pump, and be spray into fine drops through atomizer. Feeding flux of liquid pump, nozzle disc size is adjustable inorder to achieve ball granuled powder, specially for big granule size product.Working process is liquid will pass through mono pump and get into nozzle to spray up and then fall down with hot air in the same direction. Most of big granuled powder will be collected at bottom of spray dryer.Dust and fine powder will be separated by cyclone.After separating, fine powder will be collected at bottom of cyclone, the exhaust air will be draft to atmosphere by exhuast fan.Fabricating material is AISI304. Between spray tower inside and outside surface, there is insulating material. Cleaning door, inspection glass , light and control instruments, temperature sensor will be displayed and controlled on electric cabinet. Heating source is indirect heater group which is insulated by ceramic fiber and cover with stainless teel shell.Working Principle and Characteristic工 作 原 理本机的工作原理是空气通过过滤器和加热装置后，进入干燥室顶部的热风分配器，通过热风分配器的热空气均匀得进入干燥室内，并呈螺旋状流动，同时将料液送到装置在干燥室顶部的离心喷雾头，料液被雾化成极小的雾状液滴，使料液和热空气接触的表面积大大增加，水份迅速蒸发，在极短的时间内干燥成品。 Afterbeen filtered and heated(by electric heating group ) the air enters into the air distributor on the top of the dryer. The hot air enters into the drying room in spiral form and uniformly blow to inner chamber from up to down. Passing through the high-speed centrifugal atomizer on the top of the tower, the material liquid will rotate and be sprayed into the extremely fine mist liquid beads. Through the very short time of contacting the heated air, the materials can be dried into the final products. The final products will be discharged continuously from the bottom of the drying tower and from the cyclone. The waste gas will be discharged from exhaust fan.Characteristic Of Centrifuge Spray Dryer离心喷雾干燥机的特点一、Fast Drying Speed. When the material liquid is atomized,the surface area of the material will increase greatly.In the hot-air flow,95%-98% of water can be evaporated at a moment.The time of completing the drying is only several seconds. This is especially suitable for drying the heat sensitive materials.干燥速度迅速。料液经离心喷雾后，表面积大大增加，在高温气流中，瞬间就可蒸发95-98%水份，完成干燥时间仅需几秒钟。二、Liquid drops is going in same direction with hot air. Although inlet hot air temperature is high, drying chamber will reduce immediately when hot air get in contact with sprayed liquid drops. So, raw material will not over heated. This is a nother advantage for drying heat sensitive materials.采用并流型喷雾干燥形式能使液滴与热风同方向流动，虽然热风的温度较高、但由于热风进入干燥室内立即与喷雾液滴接触，室内温度急降，不致使干燥物料受热过度，因此也适宜于热敏性物料干燥。三、Widely using area. According to material characteristics, this model of spray dryer can be used for drying product and can be also used for cooling air granulating product. Chemical Industry:Sodium fluoride(potassium),alkaline dyestuff and pigment, dyestuff intermediate, compound fertilizer, formic silicic acid, catalyst, sulphuric acid agent, amino acid, white carbon and so on. Plastics and resin: AB,ABS emulsion,uric acid resin,phenolic aldehyde resin,urea-formaldehyde resin,formaldehyde resin,polythene,poly-chlotoprene and etc. Food Industry： Fatty milk powder,protein,cocoa milk powder,substitute milk powder,egg white(yolk),food and plant,oats,chicken juice,coffee,instant dissoluble tea,seasoning meat,protein,soybean,peanut protein,hydrolysate and so forth.Sugar, corn syrup, corn starch, glucose, pectin, malt sugar, sorbic acid potassium andetc. Ceramic： aluminium oxide,ceramic tile material,magnesium oxide,talcum and so on.使用范围广。根据物料的特性可以用热风干燥，也可以用冷风造型。大批特性差异很大的产品都能用此机生产，常用的有下列各类：聚合物和树脂类，染料、颜色色料类，陶瓷、玻璃类，除锈剂、杀虫药类，碳水化合物类、乳蛋制品类，鞣酸类，屠宰场的副产品，血和鱼制品类，洗涤剂和表面活性剂类，肥料类，有机化合物类，无机化合物类。四、As drying process is finished in very short period, granule size of product keep in ball shape. Final product owns good flowability, solvability and dispersion.由于干燥过程是在瞬间完成的，产品的颗粒基本上能保持液滴近似的球状，产品具有良好的分散性，流动性和溶解性。五、Simplified production process. Spray drying is applied for 40-60% solvent. Special solid containing rate can reach 90% solid containing rate. Most of product after drying can be directly packed without sieving and granulating. Purity of product is improved.Different diameter, density and water containing rate of product can be adjusted by adjust drying condition. The whole process is easy for control and operating.生产过程简化，操作控制方便。喷雾干燥常用于湿含量40-60%的溶液，特殊物料即使湿含量高达90%，同样能一次干燥成粉状产品。大部分产品干燥后，不需要再进行粉碎和筛选，减少了生产工序，简化了生产工艺流程，提高了产品的纯度。对于产品的粒径、松密度、水份，在一定范围内，可改变操作条件进行调整，控制、管理都很方便。六、In order to keep product without polution and extend using life, we use 1Cr18Ni9Ti stainless steel material to fabricate parts which will contact with product. Control cabinet is equipped in a same construction of spray tower. So, operating and control will be easy and convenient.为使物料不受污染和延长设备寿命，凡与物料接触部分，均采用1Cr18Ni9Ti的不锈钢材料制作。为使操作方便，控制系统采用一体化操作，即在控制柜安装各部件的指示装置和启闭装置。Installation Of Centrifuge Spray Dryer离心喷雾干燥机的安装安装本机的地坪应校正水平，把干燥塔放到适当的位置后考虑排气、电器，并考虑便于操作。按电气原理图，接通电源，为确保安全生产，安装本机及电器控制柜时，必需安装好接地线。离心风机的排气出口处，应根据安装场地具体情况，由用户自己配置大于风机出风口的排风管以便把废气引出室外，不使室内湿度增加，同时降低车间噪音。 Floor for install spray dryer should be flat and smooth. Fistly, spray tower should be installed on planned floor, then install plat form, stairs,safe guard, air pipe, cyclone and hot air furnace in the place.Sealing gasket should be added between flanges, to be should of good airproof.Electric control cabinet should be installed at place where is safe and easy for operating. After connect cables between motors and control cabinet, earthing line should be equipped to be sure of safe operating.Outlet window for exhaust air should be placed according to workroom consition and environment condition. User should equip required air pipes to take exhaust air out of room from outlet window. This can reduce moisture containing rate of room air and improve operating environment.Opetation And Running Of MDR-5 Spray DryerMDR-5型高速离心喷雾干燥机注意事项一、Preparing works before operating 开机前的准备1- Check if spray tower chamber is clean, if all pipes and cyclone are properly connected. Then shut off inspection door, install collecting bottle and shut off sealing cover on top of spray dryer for mounting atomizer.2- Check if all electric is properly connected. If all instruments and earthing are in correctly working. Check if motor direction is correct.3- Check compressed air pressure reduce valve and water-air separator is connected with atomizer. Please connect liquid vessel with atomizer through liquid pipe. Fix up pipe nap, and then connect compressed air pipe. Please put atomizer in place.4- Prepare raw material.1、检查干燥塔内是否清洁，各管道及旋风分离器连接是否完好，关好观察门，装好收料瓶，盖好塔顶放置雾化器的密封盖。2、检查电器有无漏电及断路、仪表工作是否正常，电机转向是否正确。3、检查压缩空气气源的减压阀与气水分离器是否已与雾化器连接好，将分液漏斗与雾化器进料管接好，固定好胶管夹，再将压缩空气管连接好，将雾化器放置在雾化器架上。4、备好物料。二、Starting process of MDR-5 Spray dryerMDR-5离心喷雾的开机顺序1- Switch on overall powder . When inlet and outlet air temperaure regulator is working regulaly, please start exhaust fan, and open heater to adjust maximum heating capacity to preheat spray tower chamber.2- When inlet air temperature reach to required temperature, please put atomizer on top seat. Turn on compressed air machine and open air valve to adjsut pressure reduce valve. Please adjust compressed air pressure to 3-4kg/cm2, and be sure that centrifuge disc is working properly.3- When atomizer is rotating in high speed, please open liquid vessel valve and adjsut liquid pipe nap open level. To be sure that liquid is slowly feed into atomizer drop bu drop.At the same time, please care of outlet air temperature changing. Please adjust feeding flux to reach required outlet air temperature.4- Inlet and outlet air temperature depends on technical characteristic, but also depends on concentration, density, viscocity of raw material.5- Inlet air temperature should be adjusted by control air heater voltage. If you need high temperature, please enhance electric voltage, otherwise, please reduce electric voltage.6- Outlet air temperature can be adjusted by control feeding quantity of raw material. If out let air temperature is too high than required, please increase liquid feeding quantity (flux ), otherwise, please reduce liquid feeding flux.7- We can check from inspection glass and collecting bottle to inspect drying situation.1、合上总电源闸、待进、出口温度表工作正常后，开启引风机、并开启调压加热将调压加热的调压电位器调至最大处进行塔内预热。2、当进口温度达到料所需要的温度时，将雾化器放入塔顶雾化器座孔。开启空气压缩机，打开气阀并调节减压阀、将空气压力调节至3-4kg/cm2、使雾化器的离心盘运转正常。3、当雾化器高速运转后将分液漏斗的阀门打开、并调节胶管夹开度、使料液一滴滴地慢慢流入雾化器内，此时注意观察出口温度的变化情况，慢慢用流量来调节到所需的温度。4、各种物料的进、出口温度应根据其工艺特性决定，也与物料的浓度、粘度、比重等相关。5、进口温度用调压加热来控制。温度要求高，就增加电压，反之则调低电压。6、出口温度用进料量来控制，温度过高，稍稍加大流量，反之则减少流量。7、干燥时的情况，可从观察窗及收集瓶里观察到。三、Stop Process停机的过程1- Please cut off valve for liquid vessle first and then shut off liquid pipe nap.2- Please turn off compressed air machine, and shut off pressure reduce valve.When atomzier stops rotating, please take it out of seat and cover atomizer seat hole.3- Please adjust electric voltage regulator to “0”, and stop heating.4- When inelt air temperature reduce to less than 150 , please clean rest dried powder in sprau chamber. Please collect all the rest powder to bottle and shut off exhaust fan.5- Please wash spray dryer chamber , pipe and atomizer after finished above works.1、先将分液漏斗的总阀门关掉，再关闭胶管夹。2、关掉空气压缩机，再将减压阀关闭，待雾化器停止运转后，将其取出放在喷头架上并盖好雾化器座孔。3、将调压电位器关至“0”，停止加热。4、待进口温度下降至150以下时打开门，清扫塔内剩余干粉，回收至收集瓶内，关掉引风机。5、以上工作完毕后，冲洗塔内，管道及雾化器。四，Remarks During Operating注意事项1- When in normal operating, please do not to open inspection door.2- If electric sudden stops during operating, please immediately stop feeding liquid into atomizer.3- Electric heater is interlock with exhaust fan.4- After washing atomizer, please put atomizer down to up on structure. Switch off centrifuge disc, disassemble press board. So, all contact part will be washed . After that, please assemble atomizer in order.5- As feeding capacity is small in this spray dryer. So, flowability of liquid should be good, also concentration of raw material can not be high, or product will easy to stick on inside surface.1、正常工作时，切勿打开观察门。2、如遇突然停电时，请立即停止进料。3、本机电加热器与引风机连锁。4、喷头清洗，把喷头倒放在喷头架上，拧下离心盘，拆下压板，这样喷头中经过料的地方都可以清洗了，然后按次序装好待用。5、本机因喷雾量较小，喷雾料液流动性要好，浓度不宜太高，否则容易有粘壁现象。How to clean spray dryer清 洗:In order to be sure of all product contact parts clean, washing equipment is very important work.When changing product or equipment has been stoped for 24 hours without product, please do a total clean to the spray dryer.为保证干燥塔体及其管道和所有与成品接触的部件的清洁，得到第一流的产品，有规则的清洗设备是十分必要的。当产品更换品种时，或是设备已经停产24小时以上而未清洗的，应作一次全面彻底清洗。Method for cleaning洗 涤 方 法: 1- Dry clean: use brush, broom, and dust cleaner for wash first. 2-Wet clean: use 60-80 hot water for washing 3-Chemical washing: use acid , detergent powder water to wash. Asic liquid preparing process: Please prepare NHO3 to 1-2% concentration solvent. Heating temperature should be no more than 65, then wash by clean water. Lye liquid preparing process: Please prepare NaOH to 0.5-1% concentration solvent, and then wash by clean water. After wash by water and chemical, please install equipment and all parts. Please sterilize equipment for 15-30 minutes. During equipment washing, please aware that do not use Cl or any chemical contains Cl. Air filter washing, please wash air filter according to ash containing rate of air. If ash containing rate is high, please wash air filter 3-6weeks once. If low ash containing , please wash air filter 6-8weeks once.Stainless steel net in air filter shoul be mounted in frame of air filter after washing and spray oil on surface.1、干洗用刷子、扫帚、吸尘器清洗。2、湿洗用60-80的热水进行清洗。3、化学洗用碱液、酸液和各种洗涤剂清洗。酸洗：将硝酸（N HO3）配成1-2%浓度的溶液，加热温度不超过65进行洗涤，然后用清水清洗。碱洗：氢氧化钠（NaOH）配成0.5-1%浓度的溶液，加热到60-80进行洗涤，然后用清水清洗。当进行湿洗和化学洗涤后，应将设备和各部件安装好，进行高温消毒，时间15-30分钟。在本设备清洗时，应注意不能用氯及其化合物洗涤。空气过滤器的清洗，应按周围环境条件，即空气中含尘量的高低而定，一般含尘量高的3-6星期清洗一次，含尘量低的6-8星期清洗一次。其中的不锈钢细丝，用碱洗去洗涤后，仍应均匀地敷设到空气过滤器的框架内，并喷以轻质锭子油或真空泵油。 Maintain Of Atomizer离心喷头的保养Maintain of atomizer is very important as it should be smoothly working in high speed rotating condition.1- If any noise and vibrating happens during operating: please stop machine immediately and take out atomizer. Check if something block inside , if it is , please clease it properly.2- Check bearing and shell, if bearing tooth and driving parts is abnormal , please change the broken parts.3- Please change lubricate oil for rolling bearing every 150-200hours.4- After finish working, please disassemble atomizer disc and put it in water in order to wash the remained liquid inside. If it can not wash clean by water, please use brush. Thats because if any liquid remain in disc, the disc will out of balance and will affect using life of atomzier and broken inside parts.5- When disassemble atomizer, please note that never bend the axis.When assemble atomizer disc, please feed disc to control distance between shell and disc. Screw for fix atomizer disc should be fixed , and be note of loose.6- After finish work, please do not put atomizer horizentally , even whrn transportation. Or it will bend the main shaft.Please put the atomzier on special structure. 要使离心喷头在高速旋转下平稳工作，其保养是特别重要的。1、喷头在使用过程中如有杂声和振动：应立即停车，取出喷头，检查喷雾盘内有否附有残留物质，如有的话应及时进行清洗。2、检查轴承和衬套，以及轴齿轮等传动机件有否异常，如发现应及时更换损坏部件。3、为增加喷头使用寿命，滚动轴承的润滑油在150-200小时应调换一次。4、使用完毕后，应将喷雾盘拆下，浸入水中，把残留物质用水清洗干净，在用清水洗不掉时，应用刷子工具清洗，因为喷雾盘上的残留物质，会带来喷雾盘不平衡度，严重影响喷头的使用寿命和直至损坏其它机件。5、在拆装喷雾头时，应注意不能把主轴弄弯，装喷雾盘时要塞片控制盘和壳体的间隙，固定喷雾盘的螺母一定要拧紧，防止松动脱落。6、喷头工作完毕后和运输过程中切忌卧放，安装不正确，会使主轴弄弯，影响使用，安放应有固定的喷头架。Possible problem when operating and solutions生产中可能出现的问题分析During operating, some times abnormal problems will happen specially when first starts spray dryer. Also because of un-proper operating of worker, some problem is easy to happen. There are possible problems and our solution for your reference:在生产过程中，有时会出现不正常的现象，特别是新设备初次运转，在操作不熟练调节控制缺乏经验时，更容易产生一些问题，现将可能出现的问题和引起的原因及补救措施列表如下，在操作时参考：Problem出现的问题Reason原因分析Solution补救措施1产品含水量高 High moisture containing rate1、排风温度低 Low outlet air temperature1、适当减小进料量，以提高排风温度。Please reduce feeding quantity, which will increase outlet air temperature also2、干燥室内壁到处都有粘着湿粉现象。Inside surface stick with wet product1、 进料量太大，不能充分蒸发。Feeding capacity is too big and can not be evaporated2、 喷雾开始前干燥室加热不足。Do not preheat spray dryer chamber beofre drying3、 开始喷雾时，下料流量调节过大。When start spraying, discharging flux is too big4、 加入的料液不稳定，下料量时大时小。Feeding liquid flux is not stable1、适当减小进料量。 Reudce feeding quantity2、适当提高进口和出口温度 Increase inlet and outlet air temperature3、在开始喷雾时，流量要小，逐步加大，调节到适当时为止。 When start spraying, feeding flux should be small and slowing adjust to big till in good situation.4、检查管道是否堵塞。 Check if pipes are block in some where.5、 调整物料含固量，保证料液的流动性。Adjust solid containing rate of liquid, to keep good flowability. 出现的问题Problems 原因分析Reason补救措施Solution3、蒸发量降低 Evaporating capacity reduced1、 整个系统的空气量减少Air quantity in whole place reduced2、热风的进口温度偏低 Inlet air temperature is lower2、 设备有漏风现象，有冷风进入干燥室。Air leak happens and fresh air get in spray dryer chamber1、 检查离心风机的转速是否正常，Check if centrifuge fan rotating speed is regular.2、检查离心风机调节蝶阀位置是否正确。 Check if centrifuge fan adjust air valve is correct.3、检查空气过滤器及空气加热器管道是否堵塞。 Check if air filter and air heater pipe is blocked.4、检查电网电压是否正常。 Check if voltage is regular.5、检查电加热 Check electric heater.4、产成品的杂质过多 Product contains too much impurities1、空气过滤器效果不佳 Air filter is not working good2、积粉混入成品 Sticked powder contains in product3、料液纯度不高 Liquid contains impurities4、设备清洗不彻底Do not clean spray dryer properly1、检查空气过滤器中过滤材质铺设是否均匀。 Please check air filter and the filtrating media is properly installed inside.2、过滤器使用时间太长，应立即清洗。 Should clean air filter as working for too long time.3、检查热风入口处焦粉情况，克服涡流。 Check hot air inlet window part, conqure whirlpool flow .4、喷雾前应将料液过滤。 Liquid should be filtrated before drying5、重新清洗设备。 Clean the equipment again6、 产品分粒太细Powder is too fine 1、 料液含固量太低Solid containg rate is less2、进料量少Feeding capacity is less1、提高料液的含固量Increase solid containing rate of liquid2、加大进料量，相应增加进风温度Increase feeding quantity, and increase inle