LPG 喷雾干燥(中英) 说明书.doc

离心喷雾使用说明书LPG- 喷雾干燥机Spray Dryer使用说明书Operation instructionPeoples Republic of China目 录Catalogue1. 概述 General 12. 工作原理Working Principle 13. 设备特点Equipment Features 24. 干燥机组的安装Dryer Installation 35. 离心喷雾干燥机操作程序Operation Procedure of Spray Dryer 3(1) 开车前的准备工作 Preparation Before Start-up(2) 开车运行 Start-up(3) 停车 Stop Running(4) 停车后的清洗 Cleaning After Stop6. 高速雾化器的维修与保养 Maintenance of High-speed Atomizer 47. 故障分析与排除Fail Analysis and Repair 68. 安全生产Safety Operation 79. 离心喷雾自控系统Auto-control System of Centrifugal Spray 810. 喷雾干燥塔中主要易损件Main Wearing Part of Spray Drying Tower 9附：电气原理图；Attachment: Electrical Principle Dwg.1. 概述 GeneralLPG型高速离心喷雾干燥机，主要用于使稀溶液、乳浊液、悬浮液、浆状物料、熔融液及中药浸膏等物料喷雾干燥成干粉。具有速度快、效率高、工序少等优点。对热敏性物料可保持其色、香、味。干粉溶解性好，纯度高，该型喷雾干燥机可广泛用于塑料、染料、轻工业、化肥、食品、医药，特别是热敏性物料，如牛奶、药物、染料等工业领域广泛使用。 LPG High-speed Centrifugal Spray Dryer mainly used for the drying of materials such as weak solution, emulsion, suspending liquid, slurry, melt-water, Chinese herbal extract etc. to dry powder. It has advantages of high speed and efficiency as well as less process. For thermal sensitive material, it can keep its color, scent and taste. Dry powder has good solubility and high purity. This kind of dryer has widely application on industries such as plastic, dye stuff, light industry, fertilizer, food-stuff, pharmaceutical especially for heat-sensitive materials such as milk, medicine, dye stuff etc.2. 工作原理Working PrincipleLPG喷雾干燥机是将需雾化的料液直接干燥成固体粉粒的过程。干燥是传热和传质同时进行的过程。在干燥过程中，前一种是液滴中水分的蒸发，主要是热交换过程。当进入降速干燥阶段后是颗粒的干燥，主要是扩散过程。物料离开干燥室时所含的水分与前一瞬时所接触的空气的相对湿度有关，物料的最终产品水分不可能低于该相对湿度下相应的平衡水分。产品的最终水分应受与其最后接触空气的相对湿度控制，是扩散控制中的湿度梯度控制，这三个控制阶段构成了喷雾干燥过程。 The drying procedure of LPG spray dryer is the drying from atomized slurry to powder directly and the heat transfer and medium transfer are carried out at the same time. During drying, water evaporation of droplet is in the process of heating exchange. When it is in lower speed granule drying, it starts the process of diffusion. The water content of discharged material from drying chamber is related to the previous air relative humidity. Final moisture of material must not lower than the balance moisture under relative humidity. Final moisture is controlled by the last time moisture humidity contacting with air and is a humidity gradient control of diffusion control, and these three control stages constructed spray drying process.已经加热至需要温度的空气以切线方向进入热风分配器，经热风分配器作用后的空气均匀地、螺旋式地进入干燥室，同时料液由雾化器雾化为伞状细小的雾滴，当雾滴与热空气混合接触后传热传质，这时高温气流与高含水率的雾滴相遇，水分迅速汽化。干燥后产品从燥室锥底进入风管随空气流入旋风除尘器,大部分物料被分离，少量细粉继续进入布袋除尘器被收集,最后尾气由排风机排出系统外。 Heating air to required temperature and entering into hot air distributor in a tangent direction, and then evenly goes into the dryer chamber in a screw type. At the same time slurry is atomized to umbrella-type fine droplet by atomizer, then it start heat and medium transfer after mixing contact between droplet and hot air. At the same time high temperature air flow contact with high moisture droplet, and then moisture start evaporating quickly. Dry material discharged from bottom cone goes into cyclone separator along with air flow in the duct where most of material will be separated, a small amount of fine will be further collected in the bag filter and the off-gas will be discharged by exhaust fan.本机组采用并流式喷雾干燥，液滴与热风方向并流流动。虽然热风温度较高，但由于热风进入干燥室立即与雾化液滴接触，干燥室内温度急剧下降，不会使被干燥物料过度受热，特别适宜热敏性物料干燥。排出产品的温度一般低于排风温度1020左右。This set of equipment is in a concurrent flow spray drying which slurry and hot air direction will flow concurrently. Although hot air temperature is much high, because of the immediate contacting between hot air in the chamber and atomized droplet, temperature in the drying chamber will decrease rapidly thus material will not be over heated, and this is especially applicable for the drying of thermal sensitive material. The temperature of discharged products is usually 1020 lower than air discharge temperature.雾化器旋转方向与热风旋转方向相同，采用逆向旋转。 Rotary speed of atomizer has the same direction with hot air rotation, both are reversal rotating.3. 设备特点Equipment Feature本设备参照中华人民共和国机械行业标准JB/T8714-1998离心喷雾干燥机的规范进行制造。This equipment is fabricated according to Chinese standard JB/T8714-1998 of Centrifugal Spray Dryer.干燥塔锥体角度设计成小于等于60，锥体上安装有空气震击器，保证粉料流畅地滑落到底部，避免粉料吸附在塔壁时间太长而产生焦化或熔融现象。Cone angle of dryer tower is designed less than 60, theres air bumper jars on the cone to make sure powder could flow to bottom smoothly thus avoid coking and fusion caused by long stick of powder to the tower wall.物料的适宜数据：适用于喷干含固率2060的料液。Applicable data of material: it is applicable for 2060 solid content slurry.本机组所有与物料接触处均采用SUS304材料制作，因此能保证产品不受污染。All parts contact with material are SUS304 to avoid products contamination.4. 干燥机组的安装 Equipment Installation安装离心喷雾干燥机的地坪应平整坚实有强度。Floor for centrifugal spray dryer installation should be flat and have certain strength.把干燥塔机组安装在所需位置（按设计布置）。Install the drying tower to required place(according to design).首先安装干燥塔，然后将操作平台、护梯、风管、除尘器、过滤器装置及风机等辅机就位连接，密封部位应装上硅橡胶密封垫。First install drying tower, and then install auxiliaries such as platform, railing, air duct, cyclone, filter and fan, sealing parts should have silicon rubber sealing gasket.电器控制柜应安装在便于操作和安全的位置。Control cabinet should be installed in the safety location easy for operation.离心风机出口，应根据车间情况，由使用厂配制管道，把排风口引向室外，以减少车间内空气湿含量和降低躁音，干燥机躁声值90dB（负载）。Outlet of centrifugal fan should be arranged to the outdoor according to actual workshop situation and users piping to reduce the workshop moisture and noise, noise value of dryer should be 90dB（loading）供料系统的安装：本机组采用变频调速泵供料（莫诺泵）。泵可根据操作需要安装在干燥塔的附近位置。进料管可选用适当长度的软橡胶管引入，进料管管径由泵进料口大小确定，出料由料液泵出料管引入雾化器进料管。Installation of feeding system: this equipment feeding equipped with frequency control pump(Mono pump). Pump could installed near drying tower according to operation requirement. Feeding pipe should be rubber hose with proper length, the diameter of feeding pipe should according to the feeding size of pump, discharged material goes into the atomizer through discharge pipe of pump.5. 离心喷雾干燥机操作程序Operation Procedure of Spray Dryer(1) 开车前的准备工作Preparation before start-upA、 检查各连接件之间的密封性。 Check seals between each connection.B、 干燥塔观察清洗门是否关紧密封。 Check if the access door of drying tower is closed tightly or not.C、 接料装置与出料口之间密封是否完好。 Check the sealing between material collecting device and discharge.D、 离心风机首先用手转动，检查有无异常，检查离心风机运转方向是否正确，风机调风蝶阀有无打开。 First check the centrifugal fan manually to see if is ok and also check its running direction and air regulation butterfly valve.E、 进料泵请按使用说明书上使用方法正确使用。 Feeding pump should be operated according to its operation instruction.F、 雾化器用手转动是否灵活，并检查油标位置。油面高度应不低于油标最低刻度，不高于油面最高刻度。检查电机旋转方向是否与喷头指示的旋转方向一致。具体请查看雾化器使用说明书。 Run the atomizer to check if its flexible and also check the oil level, the height of oil level should be no lower than the minimum scale and no higher than the maximum scale. Check if the rotary direction has the same direction with sprinkler head. For details, pls. check the atomizer operation instruction.注：机组系统内严禁有杂物。Note: No foreign matter in the equipment.(2) 开车运行Start-up开机顺序：引风机进热风阀雾化器进料泵Start-up procedure: exhausthot air inlet valveatomizerfeeding pump.注意事项：先设定进风温度，当进风温度达到所需温度时，开启离心雾化器，使其旋转，当转速正常后，先喷水，使出口温度达到预定排风温度，然后迅速转换为料液，料液调节必须由小逐渐加大，否则易产生粘壁现象。注意塔体出风温度不能超过100120,以防把布袋除尘器中的布袋烧坏。Attentions: set air inlet temperature first, when the inlet air reached to required temperature, start centrifugal atomizer and rotate it, when the rotating speed goes into normal, spray water first to make sure the outlet temperature reach to required air discharging temperature, then change to slurry quickly. Slurry must be regulated from smaller to bigger to avoid wall sticky. Outlet temperature of tower should not over 100120 to avoid burning out of bags of bag filter. 喷雾正常510分钟，可从旋风收料器底部取出物料进行数据分析。Normal spraying should be 510 minutes, materials discharged from cyclone could be analyzed.(3) 停车Stop running停车顺序：停进料泵停雾化器停热风停鼓风机停引风机注意事项：停车前，必须将物料喷完，然后换上清水进行喷雾，但需保证出口温度不变。否则，剩余在干燥塔内的物料含水量将改变。用水大约5分钟，按停车顺序停车。Stopping procedure: stop feeding pumpstop atomizerstop inlet fanstop exhaust fanAttentions: all of material should be sprayed out before stopping, then and spray again by water but make sure the outlet temperature should be the same or the remained material in the tower would change its moisture. Spraying 5 minutes by water and press button to stop it.停机后，打开干燥塔观察清洗门，清扫干燥塔内壁以及雾化器附近的积粉，最后关掉引风机，取出雾化器清洗。Open the access door after equipment stopped running, clean the remain powder accumulated in the internal wall and on atomizer, then stop exhaust fan, take out the atomizer and clean it.(4) 停车后的清洗、消毒与灭菌Cleaning and sterilization after running stopped为保证干燥产品质量，设备的清洗是重要的一环，特别是容易交叉污染的物料，更需要定期清洗。清洗次数由生产厂家根据具体情况而定。清洗的部件主要是与物料接触的部分。Equipment cleaning is very important to ensure good quality, especially for easy cross-contamination material, periodically cleaning is required. Cleaning times should accord to actual situation of vendor. Cleaning parts are mainly for parts contact with material.6. 高速离心雾化器的维修与保养 Maintenance of High-speed Atomizer高速离心雾化器要求在高速下平稳工作，因此在安装时应注意塔体上端安装雾化器的法兰面必须水平，两平面间须加硅橡胶垫以防振动及漏油。High speed atomizer is required to operate stably in high speed status, thus make sure the flange surface of upper atomizer should be flat and level during installation, silicon rubber should be added between two surfaces to avoid vibration and oil leakage.保养事项Attentions:1) 该雾化器是高精度高转速的精密机器，在运转时必须垂直放置，防止大振动及碰撞，否则会引起主轴变形，产生躁音，影响使用寿命。 This atomizer has high precision and high speed and should be putted vertically during operation to avoid big vibration and collision, or the main shaft will deform and cause noise thus it may affect operation life.2) 雾化器的运转方向是俯视逆时针运转，安装及试车时，必须点动开关，确认转向准确时才能开机。否则主轴上固定雾化盘的拧紧螺帽脱出雾化盘飞出而产生严重事故。 The rotation direction of atomizer is anti-clockwise in top view. During installation and commissioning, turn on the switch temporary and check the rotary direction, then start running. Or it may cause serious accidents caused by the relief of the atomizing disk nut on the main.3) 工作前必须先启动油泵电机，在透明尼龙管内确有油通过时，才能起动主电动机。否则会因无油工作而产生高热使轴承咬死而毁机。 Start motor of oil pump first before working, main motor could be started only when theres oil flow into the transparent nylon pipe or machine my damage caused by the shaft fail due to the high heating caused by on oil working.4) 所用润滑油是30（N46）或40（N68）无灰抗磨液压油，油位必须加到油标尺规定的范围内。过高，油会超过挡油管管口而沿主轴下流到雾化盘随液体一起喷出，过低吸油管吸不上油而无油运转而产生事故。操作者应随时注意透明管内油是否畅通，如发现无油通过，必须立即停机，修复后才能生产。 All lubricant is 30（N46）or 40（N68）no dust anti-wearing hydraulic oil. Oil level should be at the range of required scale. If the level is too high, oil will over the nozzle of oil blocking pipe and flow down along with the shaft to the atomizing disk and spray with material. If the level is too low, the suction pipe can not suck oil and will cause accident due to no oil operation. Operator should keep attention if the oil in the transparent pipe flows smoothly or not, if theres no oil passing, stop running immediately and could only start again after its fixed.5) 在拆装雾化盘等零件时应特别注意不要把主轴碰弯或擦伤；在装配雾化盘时，固定雾化盘的倒螺母一定要拧紧，防止松动脱落。 Be notice that the main shaft should not be bended or scratched during the disassembling and installation of atomizing disk and so on; during the installation of atomizing disk, nut for atomizing disk must fix tightly to avoid loosing.6) 在使用过程中如发现有异常声响，或有剧烈振动的情况应立即停车检查。 If theres any noise or severe vibration during operation, stop running immediately and check it.7) 每月需更换新油一次，更换时拆下雾化盘和外罩壳，拧下机器上端的放油螺丝，待油放尽后再用生料带包上放油螺丝重新拧上，注上新油（约一公斤左右），注意油位不要超过或低于油位线。 Replace to new oil every month, during replacing, disassemble the atomizing disk and hood as well as oil discharge screw on machine, when all oil is been discharged, pack the screw with Teflon tape and screw it again, then feed fresh oil(about 1kg), make sure oil level no more or less than the level line.7. 故障分析与排除 Fail Analysis and Repair序号No.故障现象Fail原 因Reason排 除 方 法Repair1塔顶有积粉Powder accumulated on the top tower热风分配器没有调节好 Fail on the regulation of hot air distributor雾化盘喷嘴是否堵塞 Block on the nozzle of atomizing disk调节斜形导风板斜度 Regulate the slope degree of air deflector清洗喷嘴 Clean nozzle2产品水分超标More moisture on products热风温度太低 Hot air inlet temperature is too low进料量太快Feeding speed is too fast雨、雾天空气的初始湿含量过高Initial moisture is too high because of rain and fog调整进排气温度Adjust the inlet air temperature调整进料量Regulate feeding amount3物料粘壁Material stick to wall风量的变化Air amount changes料液供给不稳定Material Feeding is unstable进风温度太低Inlet air temperature is too low检查风机是否正常、系统部件阻力是否增大Check if the fan could work properly and if the parts resistance of system increased or not.调节料液供给量Regulate feeding amount提高进风温度Increase air inlet temperature4蒸发量降低Evaporation reduced系统空气量减少Air amount in system reduced热风进口温度太低Hot air inlet temperature is too low进料量不足Feeding is not enough检查风机转速是否正常、调风蝶阀调节幅度是否恰当、进风系统是否堵塞Check the fan speed, regulating amplitude of butterfly valve, also check if the inlet air system is blocked or not.检查加热系统是否正常Check heating system提高进料量Increase feeding amount5产品夹杂度高High impurity of products空气过滤器效果差Poor effect of air filter料液夹杂度高Slurry has high impurity设备清洗不彻底Incomplete cleaning of equipment焦粉混入产品Coke powder mixing to products更换或清洗空气过滤器Replace or clean air filter喷雾前过滤料液Filtering slurry before spraying彻底清洗设备Clean the equipment completely.6产品粉粒太细Product powder is too thin料液含固率太低Solid content of slurry is too low喷雾盘转速太快Rotary speed of spray disk is too fast进料量太小Feeding amount is too small提高料液含固率Increase solid content of slurry降低喷雾盘转速Reduce the speed of spray disk增大进料量Increase feeding7产品收粉率低Product collection rate is too low旋风分离器效率低Low efficiency of cyclone separator 粉末粒度小Powder particle size is too small 检查分离器底部是否漏风Check if theres air leak on the bottom of separator检查内壁及出口是否堵塞积料现象Check if the internal wall and outlet is blocked with powder or not8产品过热Products over heat干燥室气速过低Air speed is too slow in the drying chamber操作温度超过了产品耐热温度Operation temperature is more than products heat resistance temperature适当提高干燥室气速，以不产生上旋流时为正常降低热空气进口温度或增加喷液量9雾化盘堵塞Atomizing disk blocked系统中的机械杂质Mechanical impurities in system喷雾前过滤料液Filtering slurry before spraying彻底清洗原料槽、进料管设备等Clean equipment such as material slot and feeding pipes completely拆洗雾化盘Dismount atomizing disk10雾化器振动Atomizer vibration雾化器安装不水平Atomizer installation is not flat and level雾化盘主轴产生变形The main shaft of atomizing disk deformed调整雾化器水平度Adjust levelness of atomizer更换雾化盘主轴Replace the main shaft of atomizing disk8. 安全生产Safety Operation安全生产中存在二点安全事故值得注意：Two things should be attention during safety operation:1、正常检修时所发生的人员安全事故。 Operator personal accidents during maintenance2、正常生产时所发生的安全事故。 Safety accidents during normal operation对于检修时所发生的人员安全事故只要操作人员按工厂制定的正确检修规范执行即可避免。Operators should operate according to company rules of maintenance to avoid personal accidents.在喷雾干燥操作时潜在的风险是粉尘爆炸和燃烧着火，发生爆炸事故的条件大致有下面几种情况：Potential powder explosion and combustion may occur during the operation of spray dryer. The followings are some conditions for explosion: A、物料与空气的混合温度超过了物料的燃点温度，这样可能会引起爆炸；The mixing temperature of material and air is more than the ignition point of material, this may cause explosion.B、在干燥介质中有很高的含氧量，可能引起爆炸。Operation medium has high oxygen content, this may cause explosion.在喷雾干燥操作系统中发生燃烧事故的条件大致有下面几种情况：The followings are some conditions for combustion accidents:a、在料仓中贮藏的产品自燃燃烧。Self-ignition of products stored in the storage bin.b、有过热的固体颗粒进入到干燥气体中。Theres over-heat solid granule enters into the drying air.c、大量粉体在旋风分离器或管道中摩擦燃烧。 Quite a lot of powder burns in the cyclone separator and piping because of friction.d、电路故障。Circuit faile、静电放电。Static discharge预防上述的安全隐患最好的方法是正确的操作方法和符合要求的干燥介质，采用的安全措施应有一套负责安全操作的正确的操作规范。特别对于物料可燃性较差和原料含有易燃、易爆的有机溶剂，不仅要选择闭路循环干燥系统，选择合适的干燥介质（氮气、惰性气体等），还应在干燥室上设计有安全爆破装置，旋风分离器，管道也都应有相应的安全防爆措施。The best way to avoid these above accidents is to have proper operation way and drying medium. The security measures should have proper operation rules. Especially for poor flammable mat