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WIJAY Frequently Asked Questions

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How to handle the dust generated during the feeding process of small-bagged powder?

The powder in the small bags can be transported to the storage silo under negative or positive pressure. However, how should we deal with the dust generated during the feeding process? We can install a negative pressure dust collector at the feeding station, equipped with replaceable filter cartridges and a centrifugal fan. The dust collected by the dust collector will adhere to the surface of the pleated filter cartridge. When a certain amount is reached, it will be blown back to the feeding station through pulse backflushing to avoid material wastage.

the rotary valve, also known as a rotary feeder, star discharger valve, or airlock valve. The valve core of the rotary valve has blades that rotate inside a circular valve. Material in the hopper falls into the gaps between the blades due to gravity. After rotating to the discharge outlet below driven by a motor, the material falls down by gravity. The rhythmic intermittent feeding of the rotary valve can prevent phenomena like gas blocking and pipe clogging. In positive pressure and negative pressure pneumatic conveying systems, the rotary valve is a key component.

Hygroscopic materials can indeed be pneumatically conveyed, but a series of measures need to be taken to address the moisture-related issues. Firstly, preparations need to be made before conveying. This includes drying the conveying gas to reduce its initial moisture content, installing dryers to remove moisture from the gas, and preheating the conveying pipes to reduce condensation. Secondly, control the conveying speed and pressure during the process to prevent material from staying too long in the pipes and becoming damp. Installing humidity sensors for real-time monitoring can help in taking drying measures and adjusting conveying parameters promptly. Regular cleaning and maintenance of the conveying system are also essential to ensure its sealing and dryness.

 The answer is yes, but several points need to be considered when pneumatically conveying calcium powder:

  1. Safety: Pneumatic conveying systems involve high-pressure gases and fast-flowing materials, necessitating the assurance of system safety. Installing necessary safety devices like safety valves, pressure sensors, and conducting regular system checks and maintenance is crucial to prevent accidents.
  2. Pipe blockage: Calcium powder can cause pipe blockages during conveying due to high air humidity and uneven particle distribution. Measures such as periodic pipe cleaning, optimizing conveying parameters, and using anti-blocking devices can help prevent pipe blockages.
  3. Wear issues: The high-speed flow of calcium powder in pipes can lead to pipe wall wear. Choosing ceramic-lined pipes or alloy steel pipes can extend the lifespan of the pipes.

Dense phase conveying is a low-speed, high-density conveying method used to transport powdered or granular materials through pipelines to target points. It operates at lower air velocities, ensuring stable material flow within the pipes. Compared to dilute phase conveying, dense phase conveying typically operates at speeds that are one-tenth or even lower than those of dilute phase conveying, yet it conveys materials at higher densities. This approach helps reduce material breakage and pipe wear, leading to a more energy-efficient conveying process.

A bulk bag unloading station, also known as a ton bag unloading station or bulk bag unpacking machine, is used to prevent dust dispersion and its impact on the factory environment and workers during the bag opening process. Most companies nowadays use bulk bag unloading stations during feeding and bag opening processes. A bulk bag unloading station consists of hoisting mechanisms (optional), bag beating mechanisms, bag opening devices, dust removal devices, bulk bag feeding machine frames, electrical control systems, and other structures.

Dust removal in pneumatic conveying can be approached from several angles:

  1. Choosing appropriate filters like bag filters or cyclone separators.
  2. Optimizing the design of the conveying system by controlling air velocity properly to avoid excessive or insufficient speeds and reducing the number of pipe bends and connections.
  3. Installing dust collectors, fitting small dust collectors at discharge points, and sealing the unloading device.
  4. Regularly cleaning equipment to prevent dust accumulation, checking the sealing of equipment, repairing leaky areas, conducting routine maintenance on dust removal equipment, and replacing damaged parts. Wijay can design a reasonable dust removal solution based on the customer’s site conditions to create a dust-free and safe production environment.

Some enterprises rely on manual batching due to small raw material quantities, diverse types, and significant recipe variations. This mode depends on the subjectivity of operators, resulting in low accuracy, efficiency, and error-proneness in batching. Wijay’s small material batching system can address these challenges

It primarily consists of small material storage bins, discharging modules, high-precision weighing devices, control systems, etc. The small material storage bins store various materials; the discharging modules transport materials from storage bins to specified locations as needed; the high-precision weighing devices accurately measure material weights with an accuracy of up to one-thousandth, ensuring precise batching ratios; the control system is the core, capable of setting batching parameters and coordinating the operation of various components.

Widely used in industries like food and chemicals. For example, in the food industry, when producing seasonings, it can accurately blend salt, sugar, spices, etc., ensuring consistent product flavor.

In the industrial production process, traditional mechanical conveying methods have limitations such as inadequate protection for material fragility and inefficiency when handling particles of different sizes or requiring long-distance transport. Pneumatic conveying technology, powered by gas flow, can efficiently transport particle materials from one location to another, overcoming drawbacks of traditional methods. Its main advantages include effective protection of material fragility and improved efficiency in transporting particles of different sizes or over long distances. If you have pneumatic conveying needs.

pneumatic conveying can address the problem of materials not being in contact with air by using inert gases like nitrogen instead of air as the conveying power. In industries like chemicals and pharmaceuticals, where materials can react with oxygen in the air and deteriorate, using nitrogen as the conveying medium prevents material-air contact, ensuring stability and safety during transport. If you have pneumatic conveying needs, please contact us for more information.

  1. Selection and treatment of conveying gas: Selecting appropriate conveying gas, such as inert gas, can prevent nano-carbon powder from chemically reacting and agglomerating during the conveying process. And dry and filter the conveying gas to reduce the moisture and impurities in it, and reduce the probability of agglomeration caused by impurity adsorption or moisture.
  2. Optimization of conveying speed: Control the speed of pneumatic conveying. Too slow speed may cause particle deposition, and too fast speed may cause agglomeration and loss due to intensified collisions between particles and between particles and pipe walls. A reasonable conveying speed should be determined according to the characteristics of nano-carbon powder.
  3. Design of conveying pipeline: Design a smooth conveying pipeline to reduce friction and collision of particles in the pipeline, and minimize elbows and changes in pipe diameter in the pipeline to reduce particle agglomeration and deposition caused by changes in flow direction and local resistance.

Pneumatic conveying of plastic raw materials has the following advantages. 1. Efficient delivery meets production needs. With the help of compressed air, plastic particles or powders move quickly in the pipeline to achieve efficient and continuous delivery. 2. Protect materials to ensure product quality. The closed design prevents materials from contacting the outside world in the pipeline, prevents wear and pollution, and reduces dust and environmental pollution. 3. Accurate control optimizes the production process. PLC control is used throughout the process, which can monitor the material delivery status in real time, accurately adjust the delivery speed and airflow pressure, and ensure quantitative delivery. 4. Flexible configuration for long-distance delivery. It can meet different production layouts and site conditions through reasonable pipeline design and realize long-distance material delivery.

Features:

  1. High screening efficiency: The airflow drives the material to the screening area, and under the action of the filter screen rotation, materials of different particle sizes can be quickly separated.
  2. High screening accuracy: By adjusting the airflow speed, feed amount and the design of the screening chamber, particles within the required particle size range can be screened out.
  3. Continuous operation and automatic control: The inline screening machine can realize simultaneous conveying and screening, and has the functions of continuous operation and automatic control. This feature makes the inline screening machine suitable for high-yield and continuous production screening operations.
  4. Simple maintenance and cleaning: The inline screening machine has the characteristics of simple structure, easy maintenance and cleaning. This makes the equipment more convenient in daily operation and maintenance, and improves work efficiency and equipment reliability.

There are mainly the following methods for controlling the precision of pneumatic conveying of cable raw materials.

First, the speed and pressure of the conveying airflow should be accurately controlled. By installing high-precision pressure sensors and flow meters, the parameters can be adjusted according to the characteristics of the raw materials. For example, lighter raw materials use lower flow rates and pressures to avoid collision and dispersion of raw materials in the pipeline.

Secondly, the layout of the conveying pipeline should be reasonably designed. Minimize the changes in elbows and pipe diameters to ensure that the raw materials flow stably in the pipeline. And regularly check the wear and blockage of the pipeline to prevent the conveying accuracy from being affected by pipeline problems.

Advanced feeding equipment can also be used. This equipment can accurately control the feed amount and feeding time of raw materials, such as a screw feeder with automatic metering and speed regulation functions, to ensure that the raw materials enter the conveying system at a stable flow rate.

In the pneumatic conveying system, it is crucial to determine the raw material parameters. Wijay’s commonly used raw material measurement devices include the following equipment: 1. Binocular microscope, which can be used to observe the surface characteristics and particle size of the material, and then infer its repose angle and conveying characteristics. 2. Repose angle measuring instrument, which is an instrument used to measure the repose angle of powder materials, mainly used to measure the repose angle of powder materials and granular materials to determine their fluidity. 3. Shear mixer, which is a device that integrates material accelerated shearing, mixing, crushing, dispersion, emulsification and other operations. 4. Rotational viscometer, which can monitor the stability of the mixture. In many industries, such as medicine, cosmetics and food industries, the viscosity of the mixture can be used as an indicator of stability. 5. Sieve, through high-frequency vibration, the material passes through the holes of the screen evenly inside the sifter to achieve the separation of materials of different particle sizes.

The positive pressure intermittent pneumatic conveying system uses an air compressor as the air source, and is composed of a feeding device, a sending device, a pipeline, a valve, etc. It uses fully automatic PLC control to convey powdered materials. Compared with the previous low-pressure continuous conveying, it has a longer conveying distance and greater conveying capacity, and has a longer service life and lower maintenance costs.