Introduction to High-Speed Mixer Modification Large Particle Filtration Equipment and System

I. System Process Description (Highlighted Core Advantages)

This system is tailor-made for the modification production scenarios of high-speed mixers, with the core function of accurately filtering out large particle impurities in products to ensure the purity of powder products from the source, meeting the refined requirements of various high-speed mixer modification production lines. The specific process flow is clear and efficient: the materials produced by the high-speed mixer are sucked and conveyed by negative pressure through the buffer bin, then directly enter the FW630 type filter for classification and filtration. The qualified fine particle products after filtration are efficiently collected by the pulse dust collector, and a small amount of screened coarse particle products can be collected separately or returned to the modification mill for reprocessing, realizing material recycling, minimizing production loss and improving resource utilization rate.

The entire production line adopts a PLC automatic control system, with core operating parameters such as current, voltage and rotational speed displayed in real time and clearly. It is easy to operate and understand, which can not only effectively reduce the labor intensity and human errors, but also significantly improve production stability and efficiency. It perfectly adapts to the large-scale and automated production needs, saving labor costs for enterprises while ensuring stable product quality.

II. Equipment Composition and Detailed Parameters (Key Marking for Core Equipment)

The FW630 filter system is fully equipped with reasonable configuration, covering the entire production process such as feeding, modification, filtration, collection, control and dust removal. All equipment strictly complies with industry standards, and the materials and parameters are accurately adapted to the modification production scenarios of high-speed mixers to ensure the overall efficient and stable operation of the system. The specific equipment composition and parameters are as follows:

(1) Feeding and Pretreatment Equipment

• Item 1: Stainless Steel Ton Bag Unloading Station (1 set), with a volume of about 2-3 m³ (customizable according to on-site height), adopting the weight reduction method for weighing, equipped with a lower material level device and a vibration meter. The main body is made of 304 stainless steel with a built-in lower material level alarm function, effectively ensuring the stable and continuous feeding process and avoiding material breakage or overflow.
• Item 1-1: Star Unloading Valve (1 set), made of 304 stainless steel, specially used for hopper unloading. The valve plate is made of white nylon material, which is wear-resistant and durable, effectively extending the service life of the equipment and ensuring smooth unloading without jamming.
• Item 1-2: Iron Remover (1 set), whose core function is to remove iron impurities in materials, avoid the impact of iron impurities on the purity of powder products, and ensure product quality from the pretreatment link.
• Item 7-1: Stainless Steel Ton Bag Unloading Station (1 set), with a volume of about 2 m³, made of 304 stainless steel and equipped with a lower material level alarm function. It works in coordination with Item 1 unloading station to realize feeding complementation, improve feeding efficiency and adapt to feeding requirements of different batches and quantities.
• Item 7-2: Screw Unloading Valve (1 set), made of 304 stainless steel. The inner wall of the valve body is coated with polyurethane, which has the dual advantages of wear resistance and anti-material adhesion, ensuring a clean and efficient unloading process and reducing material residue.
• Item 7-3: Iron Remover (1 set), shared with Item 10-1 iron remover, which further strengthens the iron removal effect while saving equipment procurement costs, and double guarantees the material purity.

(2) Modification and Coating Equipment

• Item 2: Quantitative Spray Adding Device for Modification Additives (1 set), adopting a combined design of “manual batching + automatic spraying”, and realizing interlocking linkage with the feeding system to ensure accurate and uniform addition of additives, effectively improve the material modification effect and ensure the stable performance of modified products.
• Item 3: Modification Coating Machine (1 set), adopting an all-ceramic protection design, with a total volume of 800L and an effective volume of 560L. The mixing time of each batch of materials is 10～12min, the spindle speed can be adjusted between 330/660r/min, and it is equipped with 3 stirring paddles. The discharge compressed air pressure is controlled at 0.35～0.45MPa, and the motor power is 132Kw with frequency conversion speed regulation. It can flexibly adapt to the modification requirements of different materials with strong adaptability and good modification effect.
• Item 4: Modification Control Cabinet (1 set), mainly responsible for the power supply, power distribution and start-stop control of the modification machine, and can monitor the operation status of the modification machine in real time. When the equipment fails, it can automatically trigger the protection mechanism and remind the operators, fully ensuring the stable and safe operation of the modification link and avoiding the impact of equipment failure on the production schedule.

(3) Core Filtration Equipment (FW630 Filter)

• Item 8: FW630 Type Filter (1 set), as the core equipment of the entire system, is specially designed for the air separation and filtration scenario of modification coating. The main body is made of carbon steel + ceramic protection, equipped with a 15KW motor and supporting frequency converter speed regulation. Through the optimized flow field design, it greatly improves the filtration efficiency and precision of large particles, effectively separates large particle impurities in materials and ensures the quality of subsequent products.
• Item 8-1: Classifying Impeller (1 piece), made of wear-resistant alloy material, the surface is treated with alumina spraying and processed by high-speed dynamic balancing, which has the advantages of wear resistance and stable operation, further ensuring filtration precision and extending the service life of core components.
• Item 8-2: Pneumatic Butterfly Valve (2 sets), adopting PLC automatic control, which can freely switch the opening and closing state. The valve plate is made of nylon material with excellent sealing performance and flexible operation, ensuring the tightness and continuity of the filtration link and avoiding material leakage or air flow disorder.

(4) Material Conveying and Collecting Equipment

• Item 5: Pre-cooling Bin (1 set), the main body is made of stainless steel and the support is made of carbon steel, which is mainly used for the pre-cooling treatment of materials to reduce the material temperature, ensure the stability of subsequent filtration and collection links, and avoid the impact of high-temperature materials on equipment performance or product quality.
• Item 6: Unloading Valve (1 set), with a volume of 6L, made of carbon steel and treated with wear resistance protection, adapted to the material unloading requirements, ensuring smooth unloading without residue and guaranteeing the continuity of the conveying link.
• Item 7: Suction Tank (1 set), the inner wall of the tank is equipped with an alumina liner, which can realize the emulsification and dispersion of materials and stably convey the materials to the classifier. It has the advantages of wear resistance and corrosion resistance, adapting to the needs of long-term and high-frequency use.
• Item 7-4: Ceramic Protection Tee and Butterfly Valve (1 set each). The tee is used for the switching of secondary classified materials, and the pneumatic butterfly valve is used for cutting off or closing the pipeline. The two work in coordination to ensure smooth material conveying and avoid pipeline blockage or poor material diversion.
• Item 9: Bag Type Pulse Collector (1 set), made of carbon steel with a filtration area of about 70 m², adopting an automatic pulse jet cleaning design, and the dust emission strictly complies with national environmental protection standards. The equipment includes a complete set of components such as pressure reducing valve, pressure bin, tube sheet, electromagnetic pulse valve, polyester needle felt filter bag and keel, which can efficiently collect the filtered fine particle products with high collection efficiency and good dust control effect.
• Item 10: Pneumatic Butterfly Valve (2 sets), adopting PLC automatic control, which can freely switch the opening and closing state, made of 304 stainless steel or coated disc, adapted to the conveying scenarios of different materials, ensuring the tightness and flexibility of the conveying link.
• Item 10-1: Iron Remover (1 set), which further removes iron impurities in materials and double checks to ensure the purity of the final product and avoid the impact of iron impurities on the application effect of the product.

(5) Power and Control System

• Item 11: Centrifugal Induced Draft Fan (1 set), providing stable working air volume for the entire system. The equipment includes components such as manual air damper, shell and wind wheel, and is equipped with a set of rubber shock absorption pads. The motor power is 37KW, with stable operation and low noise, effectively reducing the noise pollution at the production site and ensuring the stable air flow of the system.
• Item 11-1: Air Flow Regulating Valve (1 set), mainly used for air flow regulation when the induced draft fan starts and fine adjustment of air volume during the production process, ensuring the stable air volume of the system and adapting to the needs of different production working conditions.
• Item 11-2: Muffler and Soft Connection (1 set), specially used for the noise reduction treatment of the induced draft fan and the soft connection of the pipeline, which can not only effectively reduce the operation noise of the induced draft fan, but also protect the pipeline interface and avoid pipeline damage caused by equipment vibration.
• Item 13: System Control Cabinet (1 set), as the control core of the entire modification and classification system, can realize the metering and adding of materials and additives, interlocking control, as well as the linkage interlocking control with high-speed mixers and classifiers. The equipment adopts OMRON frequency converter, and core components such as contactors, air switches and thermal protectors are selected from well-known brands of Chint or Delixi. It is equipped with a PLC system and automatic programs, supports single-machine manual operation during maintenance, and is with a simulated process flow chart with operation and error indicators, which is intuitive and convenient to operate and reduces the difficulty for operators to get started.

(6) Auxiliary and Environmental Protection Equipment

• Item 12: Platform and Pipeline (1 set). The pipeline in direct contact with materials is designed with ceramic liner (colorless and white glue is preferred, and colorless, transparent or white weather-resistant materials are preferred for soft connection), and the rest of the pipelines are made of carbon steel. It is equipped with 2 ton bag unloading station platforms for the convenience of operators, and the pipeline does not include the part after the muffler, adapting to on-site installation requirements.
• Item 14: MB40 Environmental Dust Collector (1 set), made of carbon steel. Attention should be paid to the impact of condensed water on the filter bag during use, and it adopts a pulse jet cleaning design with dust emission complying with national environmental protection standards. The equipment includes components such as pressure reducing valve, pressure bin, tube sheet, electromagnetic pulse valve, polyester needle felt filter bag and keel, with a built-in induced draft fan. The inlets cover 4 key points including unloading station, buffer bin and packaging machine, which fully controls the dust pollution in the production process and creates an environmentally friendly production environment.

(7) Supporting Parts to be Purchased by Customers

To ensure the normal operation of the system, customers need to add a vibrating screen (equipped with 100-mesh screen) at the bottom of the classifier main body by themselves; in addition, customers also need to purchase supporting equipment such as steel wire hoses for environmental dust removal, wires and cables, air compressors and packaging machines by themselves to ensure that the equipment can be put into production smoothly after installation.

III. Quality Assurance

• The equipment is manufactured in strict accordance with German design drawings and process technical requirements, and the production links are controlled throughout the process to ensure that the equipment quality and performance reach the leading level in the industry and meet the high-standard requirements of high-speed mixer modification production.
• Raw materials and components are all high-quality products provided by qualified suppliers, and the quality is controlled from the source to prevent unqualified materials from entering the production process and ensure the long-term stable operation of the equipment.
• CNC machine tools are used to process the precision components of the equipment to accurately control the processing precision, reduce component errors, improve the operation stability and service life of the equipment, and reduce the later maintenance cost.

IV. After-sales Service

• Installation and Commissioning: After the equipment is delivered to the customer’s factory, our company will send professional engineering and technical personnel to the site to guide the equipment installation work throughout the process. After the installation is completed, the equipment will be fully commissioned, and systematic training will be carried out for the customer’s employees to ensure the smooth commissioning of the equipment.
• Training Objectives: Through systematic training, ensure that the customer’s technical personnel master the process principles and production parameter adjustment technology proficiently; the operators can independently complete equipment operation, daily maintenance and production monitoring work; the maintenance personnel understand the structure and working principle of the main equipment and can handle common equipment failures. The total training time does not exceed one week.
• Quality Assurance Service: Provide timely and efficient on-site service. During the quality assurance period, free repair and replacement policies are implemented for equipment components with quality defects (excluding wearing parts); after the quality assurance period, only the cost is charged for maintenance, which minimizes the later operation and maintenance costs of customers and ensures the smooth progress of production.