Several Factors Affecting the Output and Energy Consumption of Vacuum Extruder

The vacuum extruder is the main equipment in the production of hollow brick in the brick and tile industry, and its performance directly affects the economic benefits of the enterprise. There are four key factors affecting the performance of the extruder: clay cylinder, reamer, machine head, machine mouth. These four factors as long as the configuration of different raw materials is reasonable, coupled with the reasonable configuration of the production process, the vacuum extruder can play its best performance.

1. Clay

At present, some brick and tile machinery companies believe that the shorter the mud tank, the better, so that the host load is small and the output is high. In fact, this is not exactly the case for vacuum extruders. The length design of mud tanks is determined by different raw materials and the properties of finished products. Raw materials with strong plasticity can be shorter, raw materials with poor plasticity should be appropriately longer, standard bricks can be appropriately shorter, and hollow bricks should be appropriately longer. Generally, the number of reamer turns in the sealing section should be more than the number of turns for forming pressure.

2. reamer

The length of the mud cylinder is not the key factor to determine the output of the extruder. While the length of the mud cylinder meets the above requirements, the arrangement of the reamer pitch is also a key factor. But the arrangement of the reamer pitch must be aimed at different raw materials. The JKR45/45-2.0 vacuum extruder of a brick factory in Jieshou, Anhui Province, has a mud tank length of 550mm, a sealing section length of 725mm, a reamer pitch arrangement of 380mm, 360 × 1.76mm and 380 × 1/2, and the raw material is plain sedimentary soil. During the test run, the output of KP1 is 6 plates/min, the mud cylinder and the head are hot, the mud strip has no toughness, and the spiral pattern is serious. After analysis, the reason is that the pitch arrangement of the reamer is unreasonable. A pair of reamer is redesigned. The pitch arrangement is 380, 330 × 1.92 and 380 × 1/2. The reamer extends into the head 4cm, the output reaches 14 plates/min, and the temperature of the head and mud tank drops. Therefore, brick and tile machinery enterprises should design different pitch arrangements for different raw materials during production. It is best to test the composition and plasticity of raw materials before test run, and then make reamer to avoid affecting the test run time.

3. Machine port

The quality of the machine mouth directly affects the quality and output of the product. Our approach is to make KP1 and non-load-bearing hollow brick openings according to the composition of local raw materials, plasticity and the actual situation of existing ordinary solid brick openings. Generally speaking, the taper of the machine mouth is controlled at about 7~8, but when the plasticity is high, the taper can be appropriately enlarged, and when the plasticity is low, the taper can be appropriately reduced. A brick factory in Changsha is made of soft shale with good plasticity. KP1 has a 155-long mouth, an outlet size of 250 × 122 and an inlet size of 300 × 185. The non-load-bearing 8-hole hollow brick mouth of a brick factory in Jieshou, Anhui is directly made of δ = 30 steel plate without taper. Anhui and county JKR50/50-2.0 mainframe, KP1 double outlet, long 140, export 250 × 250, import 285 × 285, all achieved good results.

4. Machine head

Each head shape is different, but roughly the same structure. Generally equipped with two kinds of head, sand raw material head longer, better plastic raw material head slightly shorter. However, the transition from round to square in the inner cavity of the nose must be smooth and smooth. In addition, there is also an internal machine port: the machine port is embedded in the inner cavity of the machine head. This kind of machine head is long, the length and size of the machine port can be adjusted at any time. In addition, for the hollow brick machine mouth, the production of the machine head has a combined type and the main knife plate plug-in type. All in all, the diversity of the head is the embodiment of the diversity of raw materials.

In a word, mud cylinder, reamer, head and mouth are the main factors affecting the performance of vacuum extruder, and the best combination of different raw materials can make the vacuum extruder achieve the best and optimal design performance. Therefore, for different production lines, advance research is the most important, for different customers should first study the characteristics of its raw materials and then determine its optimal design combination. At the same time, the on-site dispatching test personnel must have good quality, and can come up with the best solution for the different problems in the test run, so as to satisfy the customers, make the vacuum extruder and other auxiliary machines produced by us play their best performance, and create good economic benefits for the enterprise.

Extruders (including non-vacuum extruders and vacuum extruders) are the main equipment on the brick and tile production line. The article discusses the main measures that should be taken to save energy in the extruder from the aspects of installing reactive local compensator, rational selection of vacuum pump, screw cutter and mud cylinder design:

1. The local reactive power compensator installed in the extruder can save energy.

An energy-saving compensator is installed at the terminal of the main circuit of the motor of the extruder. This reactive local compensator can improve the power factor of the motor (generally COSΦ can be increased to about 0.95), and can save energy by more than 15%, especially for places where the load is low and the motor is far away from the transformer.

2, vacuum extruder must be reasonable selection of vacuum pump.

Due to the extensive operation of some brick machine factories for a long time, the vacuum extruder has been using high-power vacuum pumps to cause serious energy waste. Due to the poor sealing, the general 450mm vacuum extruder uses a 22KW vacuum pump, and the vacuum degree is often not up to the requirements. In recent years, some brick machine manufacturers have made some improvements to the sealing part of the vacuum system, and the performance of the vacuum pump has also been greatly improved. Now the 5.5KW mechanical vacuum pump can fully meet the needs of 500mm or even larger vacuum extruders.

3, the extruder to use the optimal design of the spiral reamer.

The screw reamer is the heart part of the extruder, and the quality of the screw reamer plays a decisive role in the performance of the extruder. Some extruders as long as the screw reamer and other components to make some improvements, its power consumption can be reduced by 20%-30%, while the output can be increased by 20%-30%, the effect of power saving is amazing.

4. Improving the mud cylinder of the extruder can reduce energy consumption.

The length of the mud tank is also an important factor. Some brick factories think that the longer the mud tank, the better to make the mud tank very long. As a result, it not only consumes a lot of power, but also reduces the quality of the mud tank heating bricks. Generally speaking, the closed length of the spiral reamer is up to 3 pitches, which is too long to be necessary.

5. The extruder is the most energy-efficient when running at the best speed.

Some brick factories always think that the higher the speed of the extruder, the higher the output, so that the energy consumption per ten thousand bricks is low. However, in fact, in the case of the same raw materials and working conditions, there is only one optimal number of revolutions. Tests have proved that the extruder consumes the lowest energy when running at the optimal speed, and the output is also high. After exceeding this number of revolutions, the output does not increase but the energy consumption has increased significantly.

6, strengthen production management can also make the extruder energy saving

Some brick factories have the same production equipment, production raw materials and production processes, but the power consumption of 10,000 bricks is very different. The main reason is poor management. For example, in the production process, the feed is sometimes too little, sometimes the extruder does not have enough to eat, and the output is low; sometimes the feed is too much, the extruder "expands the cylinder", and often has to stop and clean up, reducing the output of the machine. Some brick factories do not match the front and back processes properly, or they cannot supply raw materials, or they cannot transport bricks. They often have to stop production. If the natural output does not go up, the relative power consumption will increase. There are also some brick factories that do not repair on time, the mud cylinder bushing is smoothed and not replaced, and the gap between the reamer and the bushing is more than 20mm without welding. These factors will increase the energy consumption of the extruder and the bushing.