许辉明-冷却器培训.ppt

1、1,SakchaiBoamoon,FeedmillKnowledgeBase,冷却过程COOLINGPROCESS,2,冷却过程COOLINGPROCESS,冷却过程是在一定的时间内将产品的温度和水分平衡到标准质量状态的一种热交换过程。Theprocessbalancedtemperatureandhumidityoftheproducttostandardqualitywithinlimitedtime,定义/Definition,3,温度平衡TEMPERATUREEQUILIBRIUM,热通过蒸发过程而变成水蒸汽HEATUSEDFOREVAPORATIONPROCESSTOVAPOR热通过

2、热的传播过程传递到冷却介质上HEATTRANSFERTOCOOLANT(MOISTAIR)THROUGHTHERMALDIFFUSIONPROCESS,4,-毛细管作用造成的液体流动LIQUIDMOVEMENTDUETOCAPILLARITY渗透力造成的液体流动LIQUIDMOVEMENTDUETOOSMOTICFORCE-水份差异造成的液体流动（液体扩散作用）LIQUIDMOVEMENTDUETOMOISTURECONCENTRATIONDIFFERENCE(LIQUIDDIFFUSION),温度平衡TEMPERATUREEQUILIBRIUM,5,-重力造成的液体流动LIQUIDMOVEM

3、ENTDUETOGRAVITY-水份差异造成的蒸汽流动（蒸汽扩散作用）VAPORMOVEMENTDUETOMOISTURECONCENTRATIONDIFFERENCE(VAPORDIFFUSION)-温度差异造成的蒸汽流动（热扩散作用）VAPORMOVEMENTDUETOTEMPERATUREDIFFERENCE(THERMALDIFFUSION),温度平衡TEMPERATUREEQUILIBRIUM,6,冷却过程CoolingProcess,1.蒸发EVAPORATION2.热扩散THERMALDIFFUSION3.机械或化学力造成的液体流动LiquidmovementbyMechanic

4、al蒸发34KGs.水需要的热量So;Heatusedtoevaporatewater34KGs.=34*2,360KJ.=80,240KJ颗粒必须传递的热量Heatmustbetransferredfrompellets=80,240-102,600=22,360KJ.,24,空气体积需要量:/Airvolumerequired:由Q=mc(t2-t1)故;22,360=m*1*(45-30)空气重量需要量(m)./Airweightrequired(m)=22,360/15=1,490KGs单位空气体积重量/Weightofairbyvolume=1.2KGs./1m3故;空气体积需要量/

5、So;Airvolumerequired=1,490/1.2=1,240m3估计的空气体积需要量1,200m3/ton-颗粒Estimatedairvolumerequire1,200m3/ton-pellets,冷却过程空气体积需要量AirVolumeforCoolingProcess,25,颗粒位置与空气流量对环境空气与颗粒间的蒸发和热扩散的影响EvaporationandThermalDiffusionEffectedbetweenAmbientAirandPelletsatDifferentLayerAndDifferentAirVolume,26,冷却器后颗粒温度、水份与空气流量之间

6、的关系RelationofTemperature,MoistureofpelletsaftercoolerandAirVolume,低温,低水份LowTemp.,LowMoisture,高温，高水份HighestTemp.,HighestMoisture,1800m3/t,正常温度，正常水份NormalTemp.,NormalMoisture,27,空气流速过高的影响EffectedfromExcessiveAirVelocity,滑动式排料机构的适宜气流速度:1.2m/s(在冷却机最大产能上)翻板式排料机构的适宜气流速度:1.3m/s(在冷却机最大产能上),Appropriateairvel

7、ocityforSlideGridDischargeSystem:1.2m/satmaxcoolercapacityAppropriateairvelocityforSwivelValveDischargeSystem:1.3m/satmaxcoolercapacity,28,不能排料或排料不连续;Cannotdischargepelletsfromcoolerorinconsistentdischarge颗粒开裂或风道吸入粉尘;Crackedpelletsordustissuckeduptoairduct.料层一直上下移动,使颗粒料在冷却器中停留时间变化不定。因而造成颗粒料排出冷却器后有效水

8、份和温度不均。Pelletslayermoveupanddownallthetimeandcausethetimeofpelletsincooleraredifferent.Sotheseeffectmoistureandtemperatureafterdischargecoolerareuneven.引起料层出现空洞，使多数冷却空气由此穿过。Causeoftheholesintheproductlayer.Somostairisflowedthroughthesehole,空气流速过高的影响EffectedfromExcessiveAirVelocity,29,30,逆流式冷却器的主要部件I

9、mportantcomponentofCOUNTERFLOWCOOLER,1.喂料闭风器INLETROTARYVALVE2.顶盖/HOOD3.分料器/PRODUCTDISTRIBUTOR4.冷却室/COOLERBIN5.排料门/DISCHARGEGATE6.支架/SUPPORTFRAME7.集料斗/COLLECTINGHOPPER8.排料传感器DISCHARGELEVELSENSOR9.溢料传感器OVERFLOWLEVELSENSOR10.装有着火调温器的出风管AIROUTLETWITHFIRETHERMOSTAT,31,逆流式冷却器的附属部件AccessorypartofCOUNTERFLO

10、WCOOLER,32,固定分料器/STATIONARYPRODUCTDISTRIBUTOR,分料器PRODUCTDISTRIBUTOR,1.在上下与水平方向上调节分料器以使颗粒料进入冷却机箱体时分散均匀。Adjustproductdistributorverticallyandhorizontallyfordistributepelletstothecoolerhousing.2.调节分料器中间间隙，以控制颗粒料在中间位置和四周的数量。Adjustthegapofproductdistributorforcontrolpelletsquantityatthemiddleandthecorner

11、ofcooler,33,旋转分料器/ROTATINGPRODUCTDISTRIBUTOR,分料器PRODUCTDISTRIBUTOR,34,旋转分料器ROTATINGPRODUCTDISTRIBUTOR,调节分料器(1)的角度使颗粒料流经散料器进入冷却器。Adjusttheangleoftheproductdistributor(1)forcontrolthedistributionofpelletsthroughthecoolerhousing.分料板之间的距离可以靠松掉螺栓(2)来调节。下端的间隙应大于上端的间隙。Thegapbetweenthedistributortrayscanbea

12、djustedbyreleasingthebolts(2)andslidingthetrays.Thelowergapshouldbelargerthantheuppergap.,35,滑动式排料门SLIDEGRIDDISCHARGEGATE,36,顶部框（1）为固定框，中间框（2）为活动框由电机驱动,下面的工作框(3)的位置改变依靠气缸驱动TOPGRID(1)STATIONARYGRID,MIDDLEGRID(2)MOVABLEGIRDDRIVEBYMOTOR,LOWERGRID(3)CHANGEPOSITIONDRIVEBYPNUEMATICCYLINDER,排料位置/DISCHARGEM

13、OVEMENT,不排料位置/CLOSEDPOSITION,清料时，框(3)向右移动CLEANOUT(3)MOVETORIGHT,动力切断时，框(3)移动到左边POWERFAIL(3)MOVETOLEFT,滑动式排料门/SLIDEGRIDDISCHARGEGATE,37,Controlcircuit,38,翻板式排料门SWIVELVALVEDISCHARGEGATE,39,关闭位置CLOSEDPOSITION,打开位置OPENPOSITION,清料位置CLEANOUT,翻板式排料门SWIVELVALVEDISCHARGEGATE,40,翻板式排料门SWIVELVALVEDISCHARGEGATE

14、,41,关闭位置CLOSEDPOSITION,打开位置OPENPOSITION,清料位置CLEANOUT,翻板式排料门SWIVELVALVEDISCHARGEGATE,42,Timerfordelaydischargetimeofthenextstroke.,When“CleanOut”CircuitwillforceOpensolenoid.,控制电路Controlcircuit,43,溢料料位传感器OVERFLOWLEVELSENSOR当颗粒料触到这个传感器执行部位时，控制电路切断制粒机喂料器。Whentheproductreachestheactivepartofthissensor,t

15、hecontrolcircuitwillswitchoffthepelletmillfeeder,排料料位传感器DISCHARGELEVELSENSOR当颗粒料触到这个传感器执行部位时，控制电路接通排料门进行排料。调节排料料位传感器高度，可以影响到颗粒料在冷却器里的停留时间。如果蒸发过程获得足够的进风量，颗粒水份和温度就会变化。Whentheproductreachestheactivepartofthissensor,thecontrolcircuitwillswitchonthecoolerdischargegate.Byadjustthedischargelevelsensorthise

16、ffecttothetimethatpelletbeinthecooler.Ifthereareenoughairvolumeforevaporationprocess,thenthepelletsmoistureandtemperaturechanged,OVERFLOWSENSOR,DISCHARGESENSOR,ROTARYPADDLELEVELSENSOR,料位传感器Levelsensor,44,由于制粒机或熟化机过热，冷却器里可能会发生着火情况。探测到着火温度时，着火调温器就会停止排风风机和关闭风闸。Duetooverheatinginapelletmillorexpanderafi

17、remightoccurinthecooler.Uponfirethethermostatstopstheexhaustfanandclosesdamper,通常，应按将着火控制温度点调整到比出风口温度约高出10C但不超过75CNormally,setpointtemperatureshouldmorethanairoutlettemperatureabout10Cornotover75C,着火调温器/FIRETHERMOSTAT,45,逆流式冷却器的调整与操作AdjustmentandOperationCOUNTERFLOWCOOLER,46,逆流式冷却器的调整与操作Adjustmentan

18、dOperationCOUNTERFLOWCOOLER,1.运行前的调整Adjustmentbeforeoperation2.分料器调整Pelletdistributionadjustment3.颗粒在冷却器内停留时间Dwelltimeofpelletincooler4.排料速度Pelletdischargerate5.进风量控制Airvolumecontrol6.维护保养Maintenance,47,运行前的调整AdjustmentbeforeOperation,滑动式排料门/SLIDEGRIDDISCHARGEGATE,在料门的关闭位置上，将中间框驱动凸轮的停止排料位置调节至行程（B）终端

19、松动螺栓(9,10),将限位开关（4）移动到要求位置。Adjustthestoppedpositionofdrivencamofthemiddlegridtotheendstroke(B)attheclosepositionofthegate,Loosescrew(9,10),movelimitswitch(4)totherequiredposition将中间框驱动凸轮的停止排料位置调节到与顶部框相配，使之能防止中间框产生积料。松下螺母(11),拉长或缩短这段距离，使中间框左上端靠近顶部框左下端。Adjustthestoppedpositionofthemiddlegridinproporti

20、onwiththetopgridtodefendtheremainingproductonthemiddlegrid,Loosenut(11),extendedorshortentherangeuntilthetopleftofthemiddlegridclosetothebottomleftofthetopgrid,48,3.调节下部框位置使其与中间框位置相配。Adjustthepositionofthelowergridinproportionwiththemiddlegrid-为使运行正常，清料柱塞(5)须缩进,动力切断柱塞（19）须外伸。Fornormaloperationthecle

21、anoutpiston(5)mustbeshrink,thepowerfailpiston(19)mustbeextend-顺时针方向转动手轮(13)到底（靠近螺母15）,在此位置，下部框离开中间框，如细节图A所示。如果从冷却器里面垂直看下去，应看不到光线通过，但沿450方向则可看见光线通过。Turnthehandwheel(13)intheclockwisedirectiontotheend(closetonut15),atthispositionthelowergridisofffromthemiddlegridasshownindetailA.ifseefrominsidecooleri

22、ntheverticaldirection,cannotseethelightpassthroughthecooler,butin450directioncanseethelightpassthrough,运行前的调整AdjustmentbeforeOperation,滑动式排料门/SLIDEGRIDDISCHARGEGATE,49,3.将下部框的位置调节至与中间框位置相配./Adjustthepositionofthelowergridinproportionwiththemiddlegrid-正常运行时，下部框的位置不应靠近主（StopBossbar）。下部框的位置应离开主止动块，如细节图

23、B所示。Innormaloperation,thelowergridpositionmustnotbeclosetotheStopBossbar.ThelowergridpositionisofffromtheStopBossbarasshowindetailB.-不生产时，动力切断柱塞（19）缩进，使下部框移动到靠住主止动块，致使中间框各处均不发生漏料。Whentheplantisblackedout,thepistonPowerFail(19)isshrankandeffecttothelowergridmoveclosetotheStopBossbar,inallpositionofth

24、emiddlegridtoprotecttheproductleakfromcooler4.将止动块(8)的位置调节至与下部框相配,/AdjustthepositionoftheStopBlock(8)inproportionwiththelowergrid.-当冷却器放空（清料）时，柱塞(5)伸出,薄片(16)须离开止动块（8）1mm。Whenthecoolerhasbeenemptied(CleanOut).Thepiston(5)extended,Sheet(16)mustbe1mmofffromtheStopBlock(8),运行前的调整AdjustmentbeforeOperatio

25、n,滑动式排料门/SLIDEGRIDDISCHARGEGATE,50,液压驱动翻板式排料机构/SWIVELVALVEDISCHARGERHYDRAULICALLYDRIVEN,用笔左右转动开口（4）检查柱塞（5）的方向，以此手动操作控制阀Operatecontrolvalvemanuallybypushingapenintherightorleftopening(4)totestthedirectionofthepiston(5)推紧笔端,顶进开口(4)10秒,在外接压力表上观察释压阀的压力。压力的调整必须使柱塞能完全打开与关闭(80Bars)。Pushthepenononesideintoo

26、pening(4)for10secondsandreadonthemanometerthepressureofthepressurereliefvalve.Thepressuremustbeadjustedinsuchawaythatthepistonopensandclosescompletely(80Bars)转动顺或逆时针方向转动旋钮（1）可以改变溢流压力大小，调整后应用锁紧螺母（2）锁紧旋钮。Theoverpressurecanbechangedbyturningknob(1)clockwiseoranticlockwise,thentheturningknobhastobelocke

27、dwithlocknut(2)afteradjusting.,运行前的调整AdjustmentbeforeOperation,51,液压驱动翻板式排料机构/SWIVELVALVEDISCHARGEGATE,限位开关（ProximitySwitch）与触头(Plexiglas)间的间隙应为0-1mm。GapbetweenProximitySwitchandPlexiglasshouldbe0-1mm限开关的作用距离应调至距传杆(3)为2mmTheproximityactiveddistanceis2mmfromthelever(3)在关闭位置，滑门（A）间的间隙应大约为颗粒料直径的3倍(10mm

28、.)AtclosePosition,thedistancebetweengate(A)shouldbeapproximately3timesofproductdiameter(10mm.)在运行开始动作位置上，打开传感器应距离关闭传感器大约20mm。Asthebeginningofoperationmovetheopenedsensorfarawayfromclosedsensorapproximately20mm,运行前的调整AdjustmentbeforeOperation,52,液压驱动翻板式排料机构SWIVELVALVEDISCHARGEGATE,运行前的调整Adjustablebef

29、oreOperation,限位开关(ProximitySwitch)与触头(Plexiglas)的间隙在1mm以内SpacebetweenProximitySwitchandPlexiglasmustbelessthan1mm.限位开关的感应部分离开传杆2mmThesensingpartofproximityswitchis2mmofffromthestick(3)在关闭位置:相邻的两个翻板之间的间隙大约是所生产颗粒料直径的三倍ClosePosition:Put“Close”switchonapproximately3xproductdiameter(d)(A=3d,Aisabout10mm.

30、),53,冷却器额定排料量调整AdjustableProductDischargeCapacityfromCooler,通过调整额定排料量至与额定进料量相匹配，就能使颗粒料层在冷却器里得到稳定，造成流经颗粒料层的空气能规则流动，从而可使冷却均匀。Byadjustdischargecapacityinproportionwithintakecapacitythiswillstabilizetheproductlayerincooler.Sotheairpassthroughtheproductlayerisregularflow,thiswilleventhecoolingprocess,顺时针

31、方向转动手轮，使下部框向左移动至与中间框具有较小的间隙，可以减小额定排料量。相反地，逆时针方向转动手轮，使下部框向左移动至与中间框具有较大的间隙，可以提高冷却器额定排料量。Byturnthehandwheelclockwise,thiswillmovethelowergridthroughtheleftcauselessgapinproportionwiththemiddlegridanddischargecapacityaredecreased.Onthecontrarybyturnthehandwheelanticlockwise,thiswillmovethelowergridthrou

32、ghtherightcausemoregapinproportionwiththemiddlegridanddischargecapacityareincreased,滑动式排料/SLIDEGRIDDISCHARGE,54,通过移动“打开传感器”(1)离开“关闭传感器”(2)，可以提高冷却器额定排料量。Bymove“OpenSensor”(1)farawayfrom“CloseSensor”(2)thiswillincreasedischargecapacityfromcooler.,翻板式排料/SWIVALVALVEDISCHARGE,1,2,通过调整额定排料量至与额定进料量相匹配，就能使颗

33、粒料层在冷却器里得到稳定，造成流经颗粒料层的空气能规则流动，从而可使冷却均匀。Byadjustdischargecapacityinproportionwithintakecapacitythiswillstabilizetheproductlayerincooler.Sotheairpassthroughtheproductlayerisregularflow,thiswilleventhecoolingprocess.,冷却器额定排料量调整AdjustableProductDischargeCapacityfromCooler,55,气流速度调节AdjustableAirFlowRate,

34、靠与控制电机电流设定值比较，采用“空气流动控制阀”来控制风闸，以调节通过颗粒料层空气的气流速度。“AIRFLOWCONTROLVALVE”controlsthedamperbycomparemotorcurrentwithsetpointfortheregularairflowratethroughtheproductlayer,56,风量不足的原因(初次运行)CausesofInadequateAirVolume(Fromthefirstoperation),风机型式不正确Usewrongtypeofexhaustfan风机太小Toosmallexhaustfan风机压力太低Toolowex

35、haustfanpressure风机速度太慢Tooslowexhaustfanspeed风门太小Toolessdamperarea风道太小Toosmallairduct沙克龙太小ToosmallCyclone,57,风量减少的原因CausesofAirVolumeDropped,风机转动方向不对Fanruninwrongdirection风道、进风口或沙克龙堵塞Duct,AirinletorCycloneareclogged风机驱动皮带松动Fandrivingbeltloosed风门关闭或损坏Damperisclosedordamaged风机速度(rpm)减少(因皮带轮变化)Fanspeed(

36、rpm)isreduced(bychangedpulley)风道、沙克龙或冷却器漏气Leakageintheairduct,cycloneorcooler风机叶片磨损Fanbladeiswornout,58,沙克龙设计及应用ApplicationandDesignedforCyclone,对不同的应用应选择不同的结构.Selectthepropercyclonefordifferentapplication,59,排风口应与沙克龙进口处在相同高度，以留下粉尘。Theairductshouldbesamelevelascycloneinletforprotecttheremainingdust.,沙克龙设计及应用ApplicationandDesignedforCyclone,60,进口设计成切向形式，以使空气流动平滑Designedtheinletastangentinletforsmoothairflow,沙