许辉明-混合技术培训.ppt

1、2020/8/17,1,混合技术 MIXING TECHNOLOGY,配料 搅拌 Proportioning - Homogenizing,2020/8/17,2,混合技术 Mixing Technology, 混合的重要性 Importance of mixing 混合定义 Definition of mixing 配料过程 Proportioning Process 配料时间及精度 Time and accuracy 原料配料指标 Raw material proportional indicator 预防性维修 Preventive maintenance 混合过程 Homogenizi

2、ng Process 分批混合 Batch wise Mixing 混合均匀度 Precision of mixing 连续混合Continuous Mixing 混合循环表Mixing Cycle Diagram 计算方法 Calculation,8/17/2020,3,混合的价值 Value of mixing,混合的效用 ;如下 Advantages of mixing consist of; 达到配方要求的原料配比 Get raw material proportion as required formula 每批的原料比例相对稳定 Regular raw materials prop

3、ortion in sample 满足均匀度 Homogeneous 使原料充分吸收添加的液体并避免成块 Raw material able to absorb adding liquid and do not agglomerate. 在规定的时间内获得稳定的优质产品 Get regular quality product within assign time 去处杂质,避免药物残留 Prevent strange matter and remainder in meat 稳定的外观质量令客户满意 Regular physical quality that make customer sat

4、isfaction,8/17/2020,4,混合的价值 Value of mixing,混合成本包括 Mixing costs consists of; 厂房的投资(折旧) Building cost (Devaluation cost, Maintenance cost) 设备的投资 (折旧,零配件, 物料消耗) Machinery cost (Devaluation cost, Spare parts cost, Consumptive parts) 劳务费 Labor cost (Operator cost, Maintenance cost) 电费,燃料费 Energy cost (E

5、lectrical cost, Steam produced cost) 其他费用(检验费) Etc., (QC accessories cost),2020/8/17,5,在足够的时间和搅动作用下,原料在混合机内运动使各种原料混合均匀. 每种原料的每一个部分都分散在整个混合物中,所以在每一处取样都能得到相同的原料成分。 The movement of raw material inside mixer causes homogeneity when there are sufficient time and turmoil. Each part or each type of raw mat

6、erial will scatter indiscriminately within the whole mass of mixture, in order, every taken samples has same raw material proportionally.,混合定义 Definition of mixing,2020/8/17,6,配料过程 Weighing Process,目标 (Target) 配料时间 Time per batch 配料准确度和精密度 Accuracy and precision,2020/8/17,7,称量时间 Time per batch,配料时间取

7、决于： Time per batch depends on : 1. 合理选用每种原料所进的配料仓,以便原料能按配方量正确进入配料秤 Selection of raw material loading to bin which has an ability to discharge to scale in proper with the amount of weight scale. 两台秤的容量尽量接近 Nearly same amount between two scales 3. 配料绞龙的能力 Ability of conveyor 4. 秤的准确度和精密度 Accuracy and

8、precision of scale 5. 设定的参数 (零位, 落差量) Parameters setting (; zero ,suspend) 6. 放料时间 Ability of discharging from scale,2020/8/17,8,准确度和精密度 Accuracy and Precision,准确度高 精密度高 Good Accuracy - Good Precision,准确度高 精密度低 Good Accuracy - Poor Precision,准确度低 精密度高 Poor Accuracy - Good Precision,准确度低 精密度低 Poor Ac

9、curacy - Poor Precision,2020/8/17,9,准确度和精密度高 Accuracy and Precision,取决于： Accuracy and Precision 配料绞龙的精度 Feeder Accuracy 配料秤的精度 Scale Accuracy 称量仪表的精度 Weight Indicator Accuracy,2020/8/17,10,喂料绞龙的精度 Feeder Accuracy,喂料绞龙的精度取决于： Feeder Accuracy depends on : 喂料绞龙设计 (高转速的小绞龙比低转速的大绞龙精度更好) Screw feeder desi

10、gn - small feeder (high revolution) is more accurate than large feeder (low revolution) 2. 喂料绞龙的使用 Screw feeder application 3. 控制系统的设计 Electrical control design 4. 机械惯性 (机械传动) Mechanical inertia (Power Transmission) 5. 电器惯性 (动作时间) Electrical inertia (Decelerate Time) 6. 料流的连续性 Continuities of convey

11、ing,2020/8/17,11,标准的配料过程 Normal Dosing,参数 P1 快进/慢进转换点 Switch fast/slow kg P2 慢进料停止点 pre cut-off weight kg r1 负偏差 (-) tolerance (-) kg r2 正偏差 (+) tolerance (+) kg t1 慢进料时间 switch time fast/slow t2 目标称量延迟时间 target dosing time slow t3 称量后落差时间 settling after dosing t4 最大称量时间 max. dosing time v2 快加料速度 do

12、sing speed fast v1 慢加料速度 dosing speed slow W1 慢加料重量 switch fast/slow kg W2 落差重量 pre cut-off weight kg,2020/8/17,KNOWLEDGEBASE DEVELOPMENT AGRO FEEDMILL BUSINESS,12,配料仓参数 Bin parameter - 正偏差 positive tolerance su - 负偏差 negative tolerance su - 慢加料点 Fine dosing section su - 落差点 Pre cut-off point su - 重

13、新称量脉冲时间（秒） Redosing pulse length (sec) - 快加料比例 Fast dosing % - 慢加料比例 Fine dosing %,配料秤参数 Scale parameter - 零偏差 (Zero tolerance) 数值 (su) - 配料时间 (Dosing supervision time) 秒(sec) - 放料时间 (Emptying supervision time) 秒(sec) - 暂停快/慢车 (Pause fast / slow) 秒(sec) - 稳定时间 (Steadying time) 秒(sec) - 清理残留时间(Residu

14、al emptying time) 秒sec) - 启动延迟时间 (Start delay) 秒(sec),称量单位 ( 数值 ) = Scale unit ( su ),配料秤容量(kg) (Scale size in kg),交/直流转换器量程 (Resolution A/D converter),配料过程分析 Dosing Algorithm,2020/8/17,13,配料器通常安装在秤斗上面,距地面数米高，故接近较困难。 Dosing elements are usually installed above the scale hoppers and several meters ab

15、ove the ground. Therefore access to them is in most cases difficult.,对配料器的要求: Requirements to dosing elements:,配料器 Dosing Elements,2020/8/17,14,配料器 配料绞龙 Dosing Element : Screw feeder,2020/8/17,15,配料绞龙要点 Screw Feeder Key Points, 送料螺距/直径比 Pitch/Diameter Ratio For Conveying - 对轻的或普通原料，最大为2/3 (0.67)； Ma

16、ximum 2/3 (0.67) for light or normal materials - 对重的或小量使用原料，最大为1/2 (0.50)； Maximum 1/2 (0.50) for heavy materials or materials used in small quantities 紧接进料口设置限料器(2倍螺距的长度)，使喂料更精确； Top shroud (2 flighting diameter length) just beyond bin outlet allow more accurate metering 限料器后面的单螺杆，容许配料绞龙低速运转，便于快速停止

17、喂料,获得高精度。 Full pitch after shroud allows feeder to run below capacity for more accurate discharge cut-off 排料口前的双螺杆或1/2叶片， 减少排料时的浪涌,使排料平稳。 Double flighting or 1/2 bare flight before discharge reduces product surging and smooth-out delivery,2020/8/17,16,配料绞龙 Screw Feeder,2020/8/17,17,配料器 : 微量喂料绞龙Dosin

18、g Element : Micro screw feeder,2020/8/17,18,配料器: 滑动插板 Dosing Element : Slide feeder,2020/8/17,19,配料器: 配料盘 Dosing Element : Bin discharge,2020/8/17,20,配料秤的精度 Scale Accuracy,配料秤的精度取决于： Scale Accuracy depends on : 秤斗形状设计 Design of scale shape 秤斗和传感器的安装 : 均衡和对称 Scale and load cell installation : center

19、and symmetrical 传感器的安装和调整 : 受力均衡 Installation and adjustment of Load Cell : balance 传感器质量 Load Cell Resolution 传感器防止受干扰 Prevention of noise signal disturb to Load Cell 原料进秤口的设计 Design of raw material intake to scale 配料顺序 Sequence of weighing 校秤频率 Frequency of Scale Calibration,2020/8/17,21,进料口布置 Bin

20、 Spout Placement,2020/8/17,22,称重仪表的精度 Weight Indicator Accuracy,称重仪表的精度取决于： Weight Indicator Accuracy depends on : 根据传感器选择仪表的型号规格和信号 Selection of type, range and signal in related with Load Cell 仪表到传感器的距离不超过设计要求 Distance from Load Cell is not more than indicated range 防止不良信号干扰 Prevention of noise si

21、gnal disturbance 仪表指示的转速和范围 Range and Revolution selection of Weight Indicator 参数设定 Parameters setting 与电脑连接方法 Communication with Computer Control 调试频率 Frequency of Weight Indicator Calibration 重量指示器 Weight Indicator,2020/8/17,23, 配料秤及配料器的精度 = 0.2 % 的额定配料量 Accuracy of Scale Partial batches down to 2

22、0 % possible 排料后残留量为 0.15 - 0.2 % Residue after discharge (try mixing) 0.15 - 0.2 % 桨叶可调整；. Adjustable paddles 维修保养方便； Easy maintenance. 仅能在转子轴长度的中间进料。 Filling only in middle third,螺带式和桨叶式的比较 Comparison between Ribbon mixer and Paddle mixer,2020/8/17,79,混合均匀度 Mixing Accuracy,2020/8/17,80,原料配比. propo

23、rtioning of components - 配料秤精度 accuracy of scales - 配料器精度 accuracy of dosing elements 原料性能 Product properties - 颗粒尺寸 particle size - 颗粒形状 particle shape - 堆放密度 bulk density 原料颗粒的尺寸 Size of component - 占整个批次的% in % of the total batch 混合机型式 Type of mixer - 混合机的设计 depending on mixer design - 混合方式 depen

24、ding on mixing tools 混合时间 Mixing time - 卧式混合机 horizontal mixers. - 立式混合机. vertical mixers 液体添加 Liquid addition - 结块情况 lump formation.,影响混合均匀度的因素The mixing accuracy influences,2020/8/17,81,借助于混合均匀度试验检查混合精确度 Check of mixing accuracy by means of a homogeneity test., 在每一个样品中跟踪所有原料是非常困难和浪费时间的。 Tracing of

25、 all ingredients in each sample very difficult and time consuming 实际上在所有样本中仅标识一种物质，用以代表其它所有原料。 In practice only one substance is identified, in all samples, serving as a representative for all of the others. 这种物质可以是混合原料中的其中一种，也可以是另外添加的 试剂。 Substance might be already in the mixture. Or a special indi

26、cator will be added.,混合均匀度试验必须考虑的事项 Points to be considered for a homogeneity test,填加试剂的位置 Adding point of indicator 取样计划 Scheme of sample taking 样本大小. 试验室分析用10 g Size of sample. 10 g for laboratory analysis 样本数量. 依混合机大小不同,为10 到 20不等 Number of samples. 10 to 20 depending on mixer size 分析方法. Method o

27、f analysis,混合均匀度试验 Homogeneity Test,2020/8/17,82,试剂 Indicator,实际上，混合均匀度的评价是通过添加一种试剂来进行的。 因此，混合物减少到一种只有“2种-原料混合物“。 In practice the homogeneity is evaluated by means of an added indicator. Therefore the mixture is reduced to a “ 2 - component mixture “,普通试剂： 甲基紫罗兰 Methyl violet Common indicators. 金属探测

28、物 Metal tracers 盐 Salt 氧化锰 Manganese oxide 铜硫酸盐 Copper sulphate,为了指示一个变化系数CV, 知道试剂在整个混合物中所占有的比例非常重要。 “稀释度” : 通常以下面的稀释度进行混合均匀度试验： To indicate a coefficient of variation CV, it is important to know what portion of the total mixture the indicator represents. “ dilution “. : Homogeneity tests are usuall

29、y carried out at a dilution 1 : 100,000 = 每 1,000 kg 为10g (1 : 100,000 = 10g per 1,000 kg),混合均匀度试验 Homogeneity Test,2020/8/17,83,为了使变化系数达到CV 5 %,试剂必须具有一定的粉率与要求的颗粒数量相匹配. (泊松分布) To achieve a coefficient of variation 5 %, the indicator must be of a certain fineness to match the required number of parti

30、cles. (Poisson distribution),一个 10g样本必须包括至少400个颗粒. A sample of 10g must contain at least 400 particles.,如果颗粒大小比要求的大, 颗粒数量较少 Are the particles larger than required and consequently less 添加的试剂数量应增加，而因此会导致较低的稀释度； the added indicator quantity must be increased, which leads to a lower dilution 采集的样本应大一些，

31、以与较大的颗粒相匹配。 The taken samples must be bigger to match the required number of particles.,10g 甲基紫罗兰 50 含有的颗粒数量与5 kg 普通盐 350含有量相同 10g Methyl violet 50 contains the same number of particles like 5 kg common salt 350.,如果不说明样本数量大小及稀释度而规定一个混合变化系数是没有意义的。 Specifying a CV without indicating size of samples an

32、d dilution does not make sense.,泊松分布 Poisson distribution,N = 颗粒平均数量 average number of particle,V = 变化系数 Coefficient of variation,混合均匀度试验 Homogeneity Test,2020/8/17,84,混合均匀度试验 Homogeneity Test,2020/8/17,85,2020/8/17,86,通过以下方法 防止分层/分级: Prevent demixing / segregation by:,避免长的输送线路. Avoiding long convey

33、ing lines. 避免高的混合料落差. Avoiding high product drops. 混合后进行添加液体 Adding liquids after mixing. 制粒 Pelleting,保持混合均匀度的方法HOW TO MAINTAIN HOMOGENEITY,2020/8/17,87,预防性维修 Preventive Maintenance,2020/8/17,88,预防性维修 Preventive Maintenance,2020/8/17,89,液体添加的位置 Liquid Fillable Point,2020/8/17,KNOWLEDGEBASE DEVELOPM

34、ENT AGRO FEEDMILL BUSINESS,90,液体添加的量Amount of Fill able Liquid at each points,2020/8/17,91,液体添加系统 Liquid Mixing Pattern,2020/8/17,92,快速混合机 桨叶的调整Paddle adjustment for High Speed Blender,2020/8/17,KNOWLEDGEBASE DEVELOPMENT AGRO FEEDMILL BUSINESS,93,糖蜜系统的设计示例 Example Design Molasses Line,2020/8/17,KNOW

35、LEDGEBASE DEVELOPMENT AGRO FEEDMILL BUSINESS,94,喷油系统的设计示例Example Design Fat Line,2020/8/17,95,混合循环图 Mixing Cycle Diagram,混合循环图的作用 The advantages of Mixing cycle diagram 显示或避免瓶颈点和等待时间 Indicate or prevent bottle-neck point and waste of waiting time 据以计算其它设备的功率和能力 Be able to calculate for other machine

36、s power and capacity 3. 得到以下数据 : Acquire the data about : - 循环时间 Cycle time - 混合机大小 Size of the mixer - 一个批次的处理时间 Processing time of a batch - 每个步骤的有效时间 Available time per process step - 空转与等待时间 Idle and waiting time,2020/8/17,96,混合循环图 Mixing Cycle Diagram,2020/8/17,97,混合循环图 Mixing Cycle Diagram,202

37、0/8/17,98,需要的主要资料 The required primary data,混合工厂的流程图 前粉碎 / 后粉碎 期望的混合产能 吨 / 小时, 批次数, 混合机大小 配方表 最少的原料用量,混合计算 Calculation about Mixing,Diagram of mixing plant Pre grinding / Post grinding Desired mixing capacity ton / hr., number of batches, mixer size List of recipes smallest component,2020/8/17,99,运行

38、要求 Operating regulation,配料 / 称重 从一种原料转换到另外一种需 4 秒 每种原料落差时间需 5 秒 配料秤排料时间 100 kg 约 15 sec. ( 100% 填满) 500 kg 约 25 sec. 2000 kg 约 50 sec. 混合 (取决于混合机型式) 10 - 20 批 / 小时 干混合时间 1.5 - 4.0 sec. 混合机放空与关闭时间10 - 30 sec.,混合计算 Calculation about Mixing,Dosing / weighing 4 sec. Switch-over from one component to the next component. 5 sec. Dribbl