1、1,冷却过程 COOLING PROCESS,冷却过程是在一定的时间内将产品 的温度和水分平衡到标准质量状态 的一种热交换过程。 The process balanced temperature and humidity of the product to standard quality within limited time,定义 / Definition,2,温度平衡 TEMPERATURE EQUILIBRIUM,热通过蒸发过程而变成水蒸汽 HEAT USED FOR EVAPORATION PROCESS TO VAPOR热通过热的传播过程传递到冷却介质上 HEAT TRANSFER
2、 TO COOLANT (MOIST AIR) THROUGH THERMAL DIFFUSION PROCESS,3,- 毛细管作用造成的液体流动 LIQUID MOVEMENT DUE TO CAPILLARITY渗透力造成的液体流动 LIQUID MOVEMENT DUE TO OSMOTIC FORCE- 水份差异造成的液体流动（液体扩散作用） LIQUID MOVEMENT DUE TO MOISTURE CONCENTRATION DIFFERENCE (LIQUID DIFFUSION),温度平衡 TEMPERATURE EQUILIBRIUM,4,- 重力造成的液体流动 LIQ
3、UID MOVEMENT DUE TO GRAVITY- 水份差异造成的蒸汽流动（蒸汽扩散作用） VAPOR MOVEMENT DUE TO MOISTURE CONCENTRATION DIFFERENCE (VAPOR DIFFUSION)- 温度差异造成的蒸汽流动（热扩散作用） VAPOR MOVEMENT DUE TO TEMPERATURE DIFFERENCE (THERMAL DIFFUSION),温度平衡 TEMPERATURE EQUILIBRIUM,5,冷却过程 Cooling Process,1. 蒸发 EVAPORATION2. 热扩散 THERMAL DIFFUSIO
4、N3. 机械或化学力造成的液体流动 Liquid movement by Mechanical & Chemical Force4. 机械或化学力造成的蒸汽流动 Vapor movement by Mechanical & Chemical Force,6,颗粒料冷却 PELLET COOLING,它是通过蒸发和热扩散过程，使料的温度和环境空气相平衡， 从而降低颗粒料温度和水份（粉状料经过蒸汽调质与制粒过程而 增加的温度与水份部分）的一种过程。 The process of decreasing temperature and moisture from pellets (which incr
5、ease by mash conditioning with steam and pelleting process.) 环境空气进入冷却器，在一定的时间内与颗粒料外表面接触，直到颗粒料温度不超过环境温度 +5 oC以上, 颗粒水份不超过 12%. by temperature and humidity balance with ambient air through the evaporation and thermal diffusion process, the ambient air is brought in contact with the outer surface of the
6、 pellets in the cooler within limited duration until the pellet Temperature is less than or equal the ambient temperature +5 oC and the pellets moisture must not be exceed 12%.,7,Cool Air,Warm Air,Vapor,Vapor,Water,Heat,温度降低原因有： Temperature Decrease by蒸发(热用于将液体变成蒸汽）Evaporation (heat used for change
7、liquid to vapor)热扩散(热传递出去) Heat Diffusion (heat transfer out)水份降低原因有： Moisture Decrease by蒸发 (蒸汽脱离) Evaporation (vapor move out)运动力 (液体脱离) Kinetic Force (liquid move out),颗粒料冷却 PELLET COOLING,8,颗粒料冷却 PELLET COOLING,40 C12%M,32 CAmbient Temp.,Heat Diffusion,32 C11%M,32 CAmbient Temp.,Heat Balance,Sur
8、face14%M,9,颗粒料冷却特性 PELLET COOLING CHARACTERISTIC,卧式冷却器 / CROSSFLOW COOLER,Air Flow,Product flow,Air Inlet Temp,Air Outlet Temp,Pellet Begin Temp,Pellet End Temp,10,逆流式（或立式）冷却器 / COUNTERFLOW COOLER,Air Flow,Product flow,Air Inlet Temp,Air Outlet Temp,Pellet Begin Temp,Pellet End Temp,颗粒料冷却特性 PELLET C
9、OOLING CHARACTERISTIC,11,颗粒料冷却曲线图 PELLET COOLING PROFILE,EvaporationStage,Thermal Diffusion,Ambient Temperature 30 CRelative Humidity 70 %,12,EvaporationStage,Liquid & VaporMovement,Ambient Temperature 30 CRelative Humidity 70 %,颗粒料冷却曲线图 PELLET COOLING PROFILE,13,冷却过程影响因素 The factors effected to coo
10、ling process.,颗粒状态 Pellets - 温度 Temperature - 水份 Moisture - 密度 Density - 大小和形状 Size & Shape - 油脂喷涂 Fat Coated,14,2. 环境空气 Ambient Air - 温度 Temperature - 相对湿度 Relative Humidity - 风量 Volume - 蒸气压力 Vapor Pressure - 空气中水份与蒸气浓度 Water content and vapor content in the air颗粒料在空气中的流动时间 Time that pellets move
11、within the air,冷却过程影响因素 The factors effected to cooling process.,15,EVAPORATION,THERMAL DIFFUSIONLIQUID& VAPOR MOVEMENT,PRODUCT IN,PRODUCT OUT,MOIST AIR IN,MOIST AIR OUT,16,影响动物消化的因素 Animal digestion factors,1. 蒸发 Evaporation - 颗粒温度 Pellet temperature - 颗粒湿度 Pellet moisture - 油脂喷涂 Fat coating - 风量 A
12、ir volume - 蒸气压力 Vapor pressure,17,2. 热传递 Heat transfer - 颗粒温度 Pellet temperature - 颗粒密度 Pellet density - 颗粒大小与形状 Pellet size and shape - 油脂喷涂 Fat coating - 风量 Air volume - 空气温度 Air temperature - 颗粒停留时间 Pellet dwell time,影响动物消化的因素 Animal digestion factors,18,3.4 因机械和化学作用造成的蒸气/液体流动 Vapor / liquid mov
13、ement by mechanical and chemical force - 颗粒水份 Pellet moisture - 颗粒密度 Pellet density - 颗粒大小与形状 Pellet size and shape - 风量 Air volume - 空气相对湿度 Relative humidity of air - 空气蒸发压力 Air vapor pressure - 空气中水份与蒸气浓度 Moisture and vapor air content - 颗粒停留时间 Pellet dwell time,影响动物消化的因素 Animal digestion factors,
14、19,冷却过程需要的风量 Air Volume Required for Cooling Process,为降低1000 KGs.颗粒料温度与水分: 进料温度 90 C 出料温度 33 C进料水份 15% 出料水份 12%采用30 C 的环境空气冷却器空气出口温度 45 CTo decrease temperature and moisture of 1000 KGs.-pellets Pellets Inlet Temp. 90 C Pellet Outlet Temp. 33 CPellets Inlet Moisture 15% Pellet Outlet Moisture 12%By
15、using the ambient air at 30C Outlet temperature from cooler 45 C,冷却过程空气需要量经验计算Practical calculation for finding air volume uses for cooling process,20,将颗粒水分从15% 降低到 12%:水分 15% 意味着颗粒 1000 KGs. 包括水 150 KGs.和干料 850 KGs.水分12%意味着颗粒 100 KGs. 由干料 88 KGs. 和水 12 KGs.组成.故此, 如干料有850 KGs. 水则有 12 x 850 /88 = 116
16、 KGs.那么蒸发掉的水就是 150-116 = 34 KGs.To decrease moisture from 15% to 12%Moisture 15% means the pellets 1000 KGs. Consist of water 150 KGs.and dry component 850 KGs.Moisture 12% means the pellets 100 KGs. Consist of dry component 88 KGs. and water 12 KGs.So,If there are dry component 850 KGs. water 12 x
17、850 /88 = 116 KGs.Then must be evaporated water 150-116 = 34 KGs.,冷却过程空气需要量经验计算Practical calculation for finding air volume uses for cooling process,冷却过程空气体积需要量 Air Volume Required for Cooling Process,21,冷却过程空气体积需要量 Air Volume for Cooling Process,自颗粒传递的热: / Heat transfer from pellets: 由: Q = mc (t2
18、- t1)Q = 1000*1.8*(33 - 90) = -102,600 KJ.将 1 KG.水蒸发变成蒸气需要的热量 = 2,360 KJ.Heat used to evaporate water 1 KG.to vapor故; 蒸发 34 KGs.水需要的热量 So; Heat used to evaporate water 34 KGs. = 34*2,360 KJ. = 80,240 KJ颗粒必须传递的热量 Heat must be transferred from pellets = 80,240 - 102,600= 22,360 KJ.,22,空气体积需要量: / Air v
19、olume required:由 Q = mc (t2 - t1)故; 22,360 = m*1*(45 - 30)空气重量需要量 (m). / Air weight required(m) = 22,360 / 15 = 1,490 KGs单位空气体积重量 / Weight of air by volume = 1.2 KGs./ 1 m3故; 空气体积需要量 / So; Air volume required = 1,490 / 1.2 = 1,240 m3估计的空气体积需要量 1,200 m3/ton-颗粒Estimated air volume require 1,200 m3/ton
20、-pellets,冷却过程空气体积需要量 Air Volume for Cooling Process,23,颗粒位置与空气流量对环境空气与颗粒间的蒸发和热扩散的影响Evaporation and Thermal Diffusion Effected between Ambient Air and Pellets at Different Layer And Different Air Volume,24,冷却器后颗粒温度、水份与空气流量之间的关系 Relation of Temperature, Moisture of pellets after cooler and Air Volume,
21、低温,低水份Low Temp., Low Moisture,高温，高水份Highest Temp., Highest Moisture, 1800 m3/t,正常温度，正常水份Normal Temp., Normal Moisture,25,空气流速过高的影响 Effected from Excessive Air Velocity,滑动式排料机构的适宜气流速度: 1.2 m/s (在冷却机最大产能上)翻板式排料机构的适宜气流速度: 1.3 m/s (在冷却机最大产能上),Appropriate air velocity for Slide Grid Discharge System : 1.
22、2 m/s at max cooler capacityAppropriate air velocity for Swivel Valve Discharge System :1.3 m/s at max cooler capacity,26,不能排料或排料不连续; Cannot discharge pellets from cooler or inconsistent discharge 颗粒开裂或风道吸入粉尘; Cracked pellets or dust is sucked up to air duct. 料层一直上下移动,使颗粒料在冷却器中停留时间变化不定。 因而造成颗粒料排出冷却器
23、后有效水份和温度不均。 Pellets layer move up and down all the time and cause the time of pellets in cooler are different. So these effect moisture and temperature after discharge cooler are uneven. 引起料层出现空洞，使多数冷却空气由此穿过。 Cause of the holes in the product layer. So most air is flowed through these hole,空气流速过高的影响
24、 Effected from Excessive Air Velocity,27,逆流式冷却器的主要部件 Important component of COUNTERFLOW COOLER,1. 喂料闭风器 INLET ROTARY VALVE2. 顶盖 / HOOD3. 分料器 / PRODUCT DISTRIBUTOR4. 冷却室 / COOLER BIN5. 排料门 / DISCHARGE GATE6. 支架 / SUPPORT FRAME7. 集料斗 / COLLECTING HOPPER8. 排料传感器 DISCHARGE LEVEL SENSOR9. 溢料传感器 OVERFLOW
25、LEVEL SENSOR10.装有着火调温器的出风管 AIR OUTLET WITH FIRE THERMOSTAT,28,逆流式冷却器的附属部件 Accessory part of COUNTERFLOW COOLER,29,固定分料器 / STATIONARY PRODUCT DISTRIBUTOR,分料器 PRODUCT DISTRIBUTOR,1. 在上下与水平方向上调节分料器以使颗粒料进入冷却机箱体时分散均匀。 Adjust product distributor vertically and horizontally for distribute pellets to the co
26、oler housing.2. 调节分料器中间间隙，以控制颗粒料在中间位置和四周的数量。 Adjust the gap of product distributor for control pellets quantity at the middle and the corner of cooler,30,旋转分料器 / ROTATING PRODUCT DISTRIBUTOR,分料器 PRODUCT DISTRIBUTOR,31,旋转分料器 ROTATING PRODUCT DISTRIBUTOR,调节分料器(1)的角度使颗粒料流经散料器进入冷却器。Adjust the angle of t
27、he product distributor(1) for control the distribution of pellets through the cooler housing.分料板之间的距离可以靠松掉螺栓(2)来调节。下端的间隙应大于上端的间隙。The gap between the distributor trays can be adjusted by releasing the bolts (2) and sliding the trays. The lower gap should be larger than the upper gap.,32,滑动式排料门 SLIDE
28、GRID DISCHARGE GATE,33,顶部框（1）为固定框，中间框（2）为活动框由电机驱动, 下面的工作框(3)的位置改变依靠气缸驱动TOP GRID(1) STATIONARY GRID, MIDDLE GRID(2) MOVABLE GIRDDRIVE BY MOTOR, LOWER GRID(3) CHANGE POSITIONDRIVE BY PNUEMATIC CYLINDER,排料位置 / DISCHARGE MOVEMENT,不排料位置 / CLOSED POSITION,清料时，框 (3) 向右移动CLEAN OUT (3) MOVE TO RIGHT,动力切断时，框
29、(3) 移动到左边POWER FAIL (3) MOVE TO LEFT,滑动式排料门 / SLIDE GRID DISCHARGE GATE,34,Control circuit,35,翻板式排料门 SWIVEL VALVE DISCHARGE GATE,36,关闭位置CLOSED POSITION,打开位置OPEN POSITION,清料位置CLEAN OUT,翻板式排料门 SWIVEL VALVE DISCHARGE GATE,37,翻板式排料门 SWIVEL VALVE DISCHARGE GATE,38,关闭位置CLOSED POSITION,打开位置OPEN POSITION,清料
30、位置CLEAN OUT,翻板式排料门 SWIVEL VALVE DISCHARGE GATE,39,Timer for delay discharge time of the next stroke.,When “Clean Out” Circuit will force Open solenoid.,控制电路 Control circuit,40,溢料料位传感器 OVERFLOW LEVEL SENSOR 当颗粒料触到这个传感器执行部位时，控制电路切断制粒机喂料器。When the product reaches the active part of this sensor, the con
31、trol circuit will switch off the pellet mill feeder,排料料位传感器 DISCHARGE LEVEL SENSOR当颗粒料触到这个传感器执行部位时，控制电路接通排料门进行排料。调节排料料位传感器高度，可以影响到颗粒料在冷却器里的停留时间。如果蒸发过程获得足够的进风量，颗粒水份和温度就会变化。When the product reaches the active part of this sensor, the control circuit will switch on the cooler discharge gate.By adjust t
32、he discharge level sensor this effect to the time that pellet be in the cooler. If there are enough air volume for evaporation process ,then the pellets moisture and temperature changed,OVERFLOW SENSOR,DISCHARGE SENSOR,ROTARY PADDLE LEVEL SENSOR,料位传感器 Level sensor,41,由于制粒机或熟化机过热，冷却器里可能会发生着火情况。探测到着火温
33、度时，着火调温器就会停止排风风机和关闭风闸。Due to overheating in a pellet mill or expander a fire might occur in the cooler. Upon fire the thermostat stops the exhaust fan and closes damper,通常，应按将着火控制温度点调整到比出风口温度约高出 10C 但不超过 75 CNormally, set point temperature should more than air outlet temperature about 10C or not ove
34、r 75 C,着火调温器 / FIRE THERMOSTAT,42,逆流式冷却器的调整与操作 Adjustment and Operation COUNTERFLOW COOLER,1. 运行前的调整 Adjustment before operation2. 分料器调整 Pellet distribution adjustment3. 颗粒在冷却器内停留时间 Dwell time of pellet in cooler4. 排料速度 Pellet discharge rate5. 进风量控制 Air volume control6. 维护保养 Maintenance,43,运行前的调整 Ad
35、justment before Operation,滑动式排料门 / SLIDE GRID DISCHARGE GATE,在料门的关闭位置上，将中间框驱动凸轮的停止排料位置调节至行程（B）终端松动螺栓 (9, 10), 将限位开关（4）移动到要求位置。 Adjust the stopped position of driven cam of the middle grid to the end stroke(B) at theclose position of the gate , Loose screw (9, 10), move limit switch (4) to the requir
36、ed position将中间框驱动凸轮的停止排料位置调节到与顶部框相配，使之能 防止中间框产 生积料。松下螺母 (11), 拉长或缩短这段距离，使中间框左上端靠近顶部框左下端。 Adjust the stopped position of the middle grid in proportion with the top grid to defendthe remaining product on the middle grid, Loose nut (11), extended or shorten the range until the top left of the middle gr
37、id close to the bottom left of the top grid,44,3. 调节下部框位置使其与中间框位置相配。 Adjust the position of the lower grid in proportion with the middle grid - 为使运行正常，清料柱塞(5) 须缩进, 动力切断柱塞（19）须外伸。 For normal operation the clean out piston(5) must be shrink, the power fail piston(19) must be extend - 顺时针方向转动手轮(13) 到底（
38、靠近螺母15）, 在此位置，下部框离开中间框，如 细节图A 所示。如果从冷却器里面垂直看下去，应看不到光线通过，但沿 450 方向则可看见光线通过。 Turn the handwheel(13) in the clockwise direction to the end (close to nut 15), at this position the lower grid is off from the middle grid as shown in detail A. if see from inside cooler in the vertical direction, can not se
39、e the light pass through the cooler, but in 450 direction can see the light pass through,运行前的调整 Adjustment before Operation,滑动式排料门 / SLIDE GRID DISCHARGE GATE,45,3.将下部框的位置调节至与中间框位置相配. / Adjust the position of the lower grid in proportion with the middle grid - 正常运行时，下部框的位置不应靠近主（ Stop Boss bar）。下部框的位
40、置应离开主止动块，如细节图B所示。 In normal operation,the lower grid position must not be close to the Stop Boss bar. The lower grid position is off from the Stop Boss bar as show in detail B. - 不生产时，动力切断柱塞（19）缩进，使下部框移动到靠住主止动块，致使中间框各处均不发生漏料。 When the plant is blacked out, the piston Power Fail(19) is shrank and eff
41、ect to the lower grid move close to the Stop Boss bar , in all position of the middle grid to protect the product leak from cooler4.将止动块(8)的位置调节至与下部框相配, / Adjust the position of the Stop Block(8) in proportion with the lower grid. - 当冷却器放空（清料）时，柱塞(5)伸出,薄片 (16) 须离开止动块（8） 1 mm。 When the cooler has bee
42、n emptied(Clean Out). The piston(5) extended, Sheet(16) must be 1 mm off from the Stop Block(8),运行前的调整 Adjustment before Operation,滑动式排料门 / SLIDE GRID DISCHARGE GATE,46,液压驱动翻板式排料机构 / SWIVEL VALVE DISCHARGER HYDRAULICALLY DRIVEN,用笔左右转动开口（4）检查柱塞（5）的方向，以此 手动操作控制阀 Operate control valve manually by pushi
43、ng a pen in the right or left opening (4) to test the direction of the piston (5) 推紧笔端,顶进开口(4)10秒,在外接压力表上观察释压 阀的压力。压力的调整必须使柱塞能完全打开与关闭 (80 Bars)。 Push the pen on one side into opening(4) for 10 seconds and read on the manometer the pressure of the pressure relief valve. The pressure must be adjusted in such a way that the piston opens and closes completely (80 Bars) 转动顺或逆时针方向转动旋钮（1）可以改变溢流压力 大小，调整后应用锁紧螺母（2）锁紧旋钮。 The overpressure can be changed by turning knob (1) clockwise or anticlockwise,then the turning knob has to be locked with lock nut(2) after adjusting.,
