| Benxi Zijin Science & Technical Exploiture Co.,Ltd |
| Tuesday,August 04,2009 Posted: 15:57 BJT(0757 GMT) |
| From:Commercial Section Article type:Original |
Mobile biomass pellets fuel equipment system Operation Manual Benxi Zijin Science & Technical Exploiture Co.,Ltd TEL: +86-414-5850432 Fax: +86-414-5850249 E-mail: ec.zjst@googlemail.com 1. Introduction The BIOY-22-Mobile biomass pellets fuel equipment system is made by Benxi Zijin Science & Technical Exploiture Co.,Ltd’s own technology and it mainly use the crop stalks and pine dust for the production of pellets fuel. Through the rational combination of the system overall structure, reduce the size of the equipment, so it can facilitate to move and transport. It is apply to village use, and can take full advantage of the scattered in rural areas but much of the total biomass straw resources. Host machine adopts gear drive system, has perfect transmission ratio. It has big driving torque, smooth transmission, easy operation and low maintenance costs. Users can choose different aperture and the compression ratio according to different needs for the best technical and economic benefits. The fuel of pellets is a clean and renewable energy sources, and it’s very convenient for production, storage and transportation. 2. Main technical parameter and performance NO. Title Parameter and performance 1 Production ability of system 200~300Kg/h 2 Energy Consumption of system ≤120kWh/t 3 Pellet density ≥1 g/cm3 4 Aperture of mould mold φ6 or φ8 5 Main motor of pellet machine 22Kw 6 Equipment size（LWH） 4300*1900*4200 7 Gross weight of equipment Almost 3.5t 3. The main structure and working principle 3.1 Process flows (See pictures below.) This system mainly by the comminutor, cyclone separating device，screw conveyer, pelletizer, windsheild machine, coolers, vibrating screen, ventilator, bag-type dust collector, and base such as composition. Process flow diagram 1. Comminutor of 11KW 2. Cyclone 3. Screw conveyer 4. Pelletizer 5. Cyclone separating device6. Windsheild machine 7. Coolers 8. Vibrating screen 9. Ventilator 10. Ventilator 11. Bag-type dust collector 3.2 Working process The system work process: After drying the biomass (water content in 12 to 18%) such as straw materials, take the material to crush in the comminutor. Transport the material through the loading auger to the mixing of pellets transportation system, and then material can enter the host machine. Under the pressure of expression roll and ring mode in host machine, the material form pallets. After being cut off by cutter through pneumatic conveyor, the cyclone separating device made of pellets transport to the cooling system. After cooling, it is adopted by the finished product after the screening, then packaged and stored. 3.3 Granulation room components 1. Compression roller component 2. Foreplate lock nut 3. Doctor frame 4. Compression roller adjuster bolt and lock nut 5. Compression roller adjustor 6. Outside shoe plate 7. Actuating shaft 8. Inside shoe plate 9. Ring mould chase 10. Ring mould 11. Top bolt 12. Scraper 13. Feeder ◇ Granulation room is the site of forming pellets, including the parts shown above. ◇ Before rebooting to check all the granulation indoor fasteners, to prevent losses caused by loose. ◇ Pre-Boot must ensure that the pressure roller bearings and spindle in a fresh grease, as detailed in "maintenance." 3.3.1 Ring mould （1）Specifications of the type Correct to choose the ring mould, namely, ring mould material and the aperture compression ratio and aperture size, is vital importance for pellets to increase the effectiveness. Ring mould general materials used alloy steel forgings, from the processing after heat treatment, wear good corrosion resistance. Ring mould aperture as the standard mode of cylindrical diameter. Type of the ring mould: Type Internal diameter of ring mould（mm） Effective width of ring mould（mm） Whole width of ring mould（mm） Thickness of ring mould（mm） Mould diameter that can produced（mm） BIOY-22 300 85 125 45 φ6、φ8 （2）Loading and unloading of ring mould The loading and unloading of ring mould should be followed the procedures below: ◇ Ensure that the power cut off before replacement pellet machine, and open the granulation room. ◇ Removal the rotation feeders of ring mould. ◇ Turn up the distance between ring mould and compression roller. ◇ Removal the ring mould chase. ◇ Use the top bolt to push out the rotor until falling off. ◇ Take off the ring mould through the expression roller. ◇ After unloading the ring mould, check with the front board scraper whether excessive wear. ◇ Clear up. The installation procedures of the ring mould should be: ◇ Note cut off power supply. ◇ Cleansing thorough the ring mould end, with cone and the inner surface. ◇ Turn the rotor, so that the ring mould touch with the rotor to ensure that it is very evenly packed in touch drive flange in the ring mould. ◇ Install the ring mould chase. ◇ Adjust the two pressure rolls and the ring moulds to the suitable location. ◇ Clean up feed pulley cone stating ring and rotation feed, and assemble them to touch the ring end. ◇ Close the pellet machine door. （3）Maintenance of ring mould Ring mould in handling attention should be paid the following: ◇ Do not let the machine running without material for a few minutes. ◇ Whenever the production or intermittently after the end of a long time, we must use oil-bearing materials to force out the raw materials out of ring mould hole. ◇ Regularly check the wear condition of ring mould. 3.3.2 Compression roller This type of pellet machine, including two each compression rollers. Compression roller contain the main compression roller eccentric shaft, compression roller shell, shock insulator, baffles, hole flexibility thackeray washer, obturating ring, round nuts, floor clip, and other components. As shown. 1. Eccentric shaft 2. Round nuts 3. Floor clip 4. Compression roller shell 5. Shock insulator 6. Bearing 7. Obturating ring （1）Compression roller shell ◇Compression roller shell is made of the wear-resistant alloy material from machining and heat treatment. （2）Loading and unloading of compression roller Removal the compression from the pellet machine: ◇ Cut off the power and open the machine door. ◇ Release the six inside hexagonal bolts of rotating feeder, and remove the rotating feeder. ◇ Release the compression adjusting bolt, and unloading it. ◇ Release the two compression roller adjustors at the end of the compression roller eccentric shaft ◇ Release the locking bolt of front shoe plate, unloading the locknut of front plate. ◇ Unloading the front shoe plate. ◇ Use wrenches to move compression roller eccentric shaft at the end of the tooth-position, and adjust the gap between compression roller and the ring mould to the maximum. ◇ Take out the compression roller. （3）The compression adjust Central-pressure roll and The gap between compression roller and ring mould whether or not to adjust appropriate relate to the machine function normally and the compression roller, ring-life. The next map is the adjust direction of the compression roller: 1. Ring mould 2. The adjust direction of the compression roller 3. Compression roller 4. The turn direction of the compression roller 5. The turn direction of the ring mould Need to pay attention： ◇ In regulation, ring mould and compression roller surface should be thoroughly cleaned, otherwise adjust the gap is untrue. ◇ The regulation of space that between compression roller and ring mould should before adding oil, then even if only a slight friction, ring-driven pressure can also turn the compression roller. ◇ Make sure that the compression roller counter-clockwise, namely the in the opposite direction to the ring mould moving direction and to near the ring mould, or else at work the compression roller may get stuck with the ring mould, resulting in the core components of machine damage. ◇ If the compression roller found too tight or too loose in the boot after start, timely adjustment. ◇ If the two compression rollers long time running and without the replacing. It should be regularly checked granulation some wearing parts of the indoor wear. ◇ Locking nut to prevent the loose. Such as the frequency of three inspections. 4. The operation of equipment system 4.1 Before starting the equipment must to check whether or not the equipment connect to the power. And also check the instruments, components are good. Check the space between the compression roller and ring mould is right (0.2 mm). 4.2 Host machine connects to the power and no-load operation; if any unusual phenomenon happened, we must immediately shut down, and find out the reasons, troubleshooting before use. 4.3 Connect to the power, switch on the main host motor and compulsory feeder motor. Host operators begin to feed gradually. After the equipment normal in good running, you can start pellet mixing motor and material transportation motor. 4.4 The use of raw materials such as straw, need to start the grinder power, and put into straw. If use powder, you can directly put the material to Screw conveyer. 4.5 After the pellets out of the machine, start the upgrade fan and cooler fan. 4.6 After pellets cooling from the cooler motor, eye survey the materials high. Achieve the high for put material, and then start vibrating screen and manually emptying. Put the pellets bags. 4.7 Operators put pellets into the bag, and transport to the warehouse. 4.8 Equipment operators at any time observation equipment parts operation, in particular the change of host current, and ensure normal operation of equipment. 4.9 In the course of operation of equipment, if the equipment had abnormal phenomenon, it should be immediately shut down. And you should with the technical staff communication, in order to take further measures. 4.10 Exhaust the materials in the hopper before shut down power, and join the oil-doped materials. To be confirmed that the ring mould has been filled with oil-doped materials, turn off the main electrical switch, clean-up the scene to prevent the accident. 4.11 The commissioning of new mould The new mould-hole, though polished, to achieve maximum production still need materials polished. If moulds have polished by materials before leave the factory, the operation may be appropriate to reduce wear-time. Grinding hole, to use materials with oil commissioning, make sure that all holes are to put out pellets (tablets of holes at least 90 per cent), re-incorporation of the friction materials, until all polished up the hole. 5. Factors affecting the pellet 5.1 The choice of mould Commissioning of new mould, attention should be paid to its production capacity and quality of particles, when one does not meet standards, to find out the reasons for the impact. If the particles of the other parts are functioning normally, we should check the mould, thickness of mould and the shape of the hole will be on productivity and the quality of particle effects, so these technical indicators should be choose appropriately. Change the thickness of the mould and pellets materials can change the hardness. Regulation of pellets quality can also increase the productivity. 5.2 The request of materials Practice has proved that to improve the efficiency of equipment and pellet quality, the equipment must have certain requirements. If the material too coarse, it will increase compression roller and ring mould wear and power consumption, reduced production and pellets quality. Therefore, the materials should be fine but not too small, otherwise the particles would be crisp. 5.3 The request of moisture To ensure the quality of pellets, the moisture content of materials has certain requirements, excessive moisture when the material will become ” comical” , causing compression roller skid. Different moisture in materials will change the friction properties and operation. When material is too dry, the friction in hole may be greater than expected pressure trying to roll out. Then, the equipment appears no produce phenomenon. The moisture has two kinds, material own water and addition. In general, the overall control of water in 12 to 18 percent suitable. 5.4 Cooling To prevent the pellets to be metamorphism and crisp at storage, the pellets must be cooled or dried in the immediate after out of the compression. Pellets temperature should be dropped to room temperature or slightly higher than the temperature 5 ~ 8 ℃, if it not immediately be cooled, the pellets will lead to fragmentation. Thereby reduce productivity and increase production costs. 6. Maintenance 6.1 Routine maintenance (referring to after a turn work) 6.1.1 Check the mould and the compression roller wear gap and wear condition, when the compression roller of wear and tear can not be transferred to the needs of space, then have to replace the compression roller (attention the two compression rollers should also adjustment and replaced at the same time). 6.1.2 Check whether there are different parts of oil spills. 6.1.3 Check the start electric line. 6.1.4 Maintain clean, clean feeder, stirring, feed bucket and mould, etc. 6.1.5 Eliminating abnormal phenomenon and fault. 6.2 Regular inspection 6.2.1 Adjust the drive shafts spindle bearing clearance once a week, and check whether the bolts loosening. 6.2.2 Wash and oiling the bearing of delivery and feeder system monthly. 6.2.3 Strip inspection and clean the whole equipment each year. Inspection of the vulnerability with the wear and tear, and gear wear condition. 6.3 The maintenance of major components 6.3.1 Feeder system: Regularly check bucket that at the top of feeder to prevent the arch camber and plug. Screw conveyor speed is controlled by the speed motor, quantity can be adjusted according to need. 6.3.2 Safety pin devices: a safety pin is composed of the inner ring safety pin and the outer ring safety pin. It is used to protect mould and roller to when enter foreign body, so as to the parts will not be damaged. When the foreign matter entry the mould and roller’s gap, the compression roller can not roll rotation, and this led compression rollers and mould rotation together, the safety pin cut, limit switches send a signal to the motor stops. 6.3.3 Compression mould: To extend the life of mould, you should pay attention to the action of mould, especially to keep mould-roughness (mould in the clockwise direction of rotation). ①Never use a heavy hammer hammering, attention the compression rollers and drive disk contact surface cleaning when installation. Regularly check the wear condition between compression roller and outside clamp should not have loosening phenomenon. When the outside clamp is wear or appears to crack, continued use is strictly prohibited. ②If a foreign body into the hole mould, must be get out . ③Forbidden welding after compression mould fracture. ④The compression mould when not in use, the oil materials must be filled in the hole. ⑤Repair of compression mould, when the mould irregularities should remove the moulds, and the polish inside surface. ⑥When the thickness become thinning, and impact on the quality of pellets or produces double-pellet, the compression mould should be a scrapped. 6.3.4 Compression roller: Two different homocentric compression rollers carefully installed in the mould, two compression rollers outer surface regulated through eccentric shaft. The adjustment of gap between compression mould and compression roller the particles is very important for the equipment. The correct adjustments will be the largest production capacity, and less friction, at the same time can eliminate the undue pressure on the machine. Adjust methods are as follows: ①Release the upper adjustment bolts of left compression roller and the bottom adjustment bolts of right compression roller. ②Anti-clockwise adjusted the gap fixing clip, if not counter-clockwise adjustment, the compression roller installed wrong, have to be re-installed. On pressuring pellets, the pressure due to wear and roll became out of round. When the machine running and mould touches the roller, it should be stopped and regulated. ③If the eccentric shaft has reached the end of regulation, the removing the compression roller and re-install it at the largest clockwise site. ④After adjustment, screw the released adjust-knob. ⑤When the groove of compression roller wear down, it can be removed and reinserted. If the regulation has no effect, replace a new one. 6.3.5 Scraper: its role is to feed materials into gap between compression mould and compression roller with the help of the compression mould rotation. Scraper is not allowed contact with the conical feeder, the gap in between 1 ~ 2 mmn, and it should be timely replacement if worn. 6.3.6 The adjustment of spindle bearing: After spindle bearing worn, the bearing wear gap should be eliminated. Loose the first back-end spindle nut screw, tighten the second nut, and then tightened the first nut. 7. Malfunction and resolution Cause of the malfunction and characteristics Fault resolution 1. Safety pin is broken, and the electrical stop rotating. ①Foreign matter wedges between compression roller and compression mould. ②Material excess plug. ①Clear the Foreign matter. ②Clean the plug, and release the material quantity. 2. Do not produce pellets 2.1 Materials can not enter mould ①Feed plug or transmission failure. ②Mixing transmission failure or plug. ③Feed hopper plug. ④Transportation system plug. 2.2 The materials into the compression mould but can not produce the pellets. ①Low moisture content of materials. ②High moisture content of materials. ③The gap between mould and roller is too big. ④Wrong scraper installed. ⑤The mould hole plugged (too thick, the replacement of materials, the mould hole not smooth enough). Troubleshooting, and clear the plug. ①Open up the mould hole or squeeze out the hard pellets. ②Adjustment the moisture content. ③gap between mould and roller. ④Adjustment scraper. ⑤Use crude materials polish the hole, if several ways have no effect can use cooking oil. 3. The pellets of uneven or poor quality ①Feed instability. ②Agitator is damaged, and uneven mixing. ③Size does not apply in the powder. ①Stable the input materials quantity. ②Repair the damage. ③Powder weight to moderate, avoid all rough materials or materials are all fine. 4. Serious operating sound ①Bearing wear, or too much gap. ②Gear mesh gap is too large. ①Gap adjustment, take replacement if serious worn. ②Replacement. 8. Wearing parts and bearing details Wearing parts details list NO. Name Type Number Installation site Remarks 1 Compression mould φ300 1 Extrusion system 2 Compression roller φ130 2 Extrusion system 3 Safety pin 2 Safety pin equipment 4 Scraper 2 Extrusion system 5 Rubber skeleton oil seal 200*240*18 1 Main bearing Gear shaft 6 Rubber skeleton oil seal 80*110*12 1 Main bearing Gear shaft 7 Rubber skeleton oil seal 45*70*12 2 Bearing cap Gear shaft 8 Rubber skeleton oil seal 90*65*12 4 Compression roller 9 Rubber skeleton oil seal 4 Mixing feeder system 10 O ring rubber 135*8.6 1 Safety pin equipment 11 Felt 1 Drive bearing cap 12 Felt 4 Mixing feeder system 13 Nylon pin 6 Shaft joint Bearing details NO. National standard Type Number Installation site Remarks 1 GB293-64 32216 1 Between drive shaft and assurance caps 2 GB293-64 2007116 1 In the assurance caps 3 GB293-64 2007130 1 Drive shaft and bearing block 4 GB298-64 2007113 1 Inside hole of drive shaft and spindle 5 GB298-64 7209 1 Primary gear shaft 6 GB270-64 210 1 Primary gear shaft 7 GB283-64 7210 4 Compression roller 9. Electrical schematics (see attached map) |
| (Source: English Site of Libyan) |
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