Analysis on common problems of quartz sand production equipment: professional
manufacturer will provide you with quick troubleshooting and solutions
Stable operation of quartz sand production equipment is the key to ensure
production efficiency and finished product quality. However, various problems
are inevitable in crushing, sand making, screening, magnetic separation and
other equipment during long-term high-load operation. As a professional
manufacturer specialized in R&D and manufacturing of quartz sand production
equipment, we have combined the practical application experience of thousands of
equipment to sort out the typical problems, causes and solutions of equipment in
each link, so as to help customers quickly troubleshoot faults and reduce
shutdown losses.
1、 Crushing equipment: how to deal with material jam, abnormal sound and
uneven particle size of finished products?
Crushing equipment (jaw crusher, cone crusher, etc.) is the "first pass" for
the production of quartz sand. Common problems mainly include material jam,
abnormal noise and particle size fluctuation of finished products.
The problem of material jam is mostly caused by oversized feed particles or
hard materials mixed in the materials. If the feed inlet of jaw crusher gets
stuck, immediately shut down the crusher and cut off the power supply. Use a
special crowbar to clean the materials stuck in the crushing chamber. Do not
touch directly with hands; The feed grain size shall be strictly controlled (not
exceeding 80% of the rated feed opening size of the equipment), and the feed
opening shall be provided with a grid to intercept stones, metals and other
foreign matters.
Unusual noises are usually associated with loose or worn parts. If the "metal
friction sound" is heard during operation, the jaw plate may be loose or the
lining plate is seriously worn. Shut down the machine to check and fasten the
bolts, and replace the lining plate with excessive wear; In case of "periodic
impact sound", the clearance of eccentric shaft bushing may be too large, and
the clearance shall be adjusted or the bushing shall be replaced.
Uneven grain size of finished products mainly results from improper
adjustment of discharge opening or uneven wear of crushing chamber. It can be
solved by adjusting the size of the discharge opening (accurate adjustment
according to the finished product requirements, such as reducing the discharge
opening for fine sand production); If the particle size deviation is caused by
local abrasion of the lining plate of the crushing chamber, the lining plate
shall be replaced in time to ensure the regular shape of the crushing
chamber.
2、 Sand making equipment: how to deal with insufficient capacity, poor sand
grain pattern and motor overload?
Sand making equipment (mainly impact sand making machine) directly affects
the grain size and productivity of quartz sand, and common problems shall be
solved in combination with equipment structure and material characteristics.
There may be three major reasons for sudden drop of capacity: first, overload
of equipment caused by excessive feeding, so feeding speed shall be reduced to
keep uniform feeding; Second, the impeller channel is blocked by materials, so
it is necessary to shut down and disassemble the impeller to clean the blocked
quartz sand particles (pay special attention to the accumulation of fine
powder); Thirdly, the wearing parts (such as impact block and liner plate) are
seriously worn and the crushing efficiency is reduced, so the wearing parts
shall be regularly inspected and replaced (it is suggested to replace them every
1-3 months according to the production frequency).
The sand grain type difference (high powder content, many needles and flakes)
is mostly related to the equipment parameter setting or material humidity. If
the powder content is too high, the airflow channel inside the vortex chamber
can be adjusted to enhance the separation effect; If the elongated and flaky
particles exceed the standard, the impeller rotating speed shall be reduced (too
high rotating speed may cause excessive crushing of particles), and the particle
size of raw materials shall be controlled at the same time (the particle size of
crushed raw materials shall not exceed the upper limit of feeding requirements
of sand making machine); If the material humidity is too high (moisture>5%),
it is easy to cause particle agglomeration, and the raw materials shall be dried
first.
Overload tripping of the motor shall be checked from "load" and "circuit"
aspects: first check whether the feeding amount exceeds the rated load of the
motor, and properly reduce the feeding; Check whether the motor wiring is loose
and whether the bearing is lack of oil. If the bearing is heated, add
lubricating grease (select high-temperature resistant lithium base grease), and
replace the bearing if it is serious.
3、 Screening equipment: how to solve problems such as low screening
efficiency, damaged screen and abnormal equipment vibration?
Screening equipment (circular vibrating screen, linear screen, etc.) is
responsible for separating quartz sand with different particle sizes, and the
problems are mostly related to the screen and vibrating system.
Low screen efficiency is the most common problem, with core causes including
clogged screens, insufficient amplitude or improper screen inclination. When the
screen is blocked, it is necessary to replace the screen with a suitable mesh
according to the particle size of the material (anti-blocking screen is
recommended for fine sand screening), and a cleaning device (such as rubber
ball) can be installed under the screen; If the amplitude is insufficient,
adjust the angle of eccentric block of vibration motor (the larger the angle is,
the larger the amplitude is, the higher the screening efficiency is, but avoid
equipment damage caused by excessive amplitude); It is suggested to control the
inclination of the screen surface within 15 ° - 20 °. Too small inclination will
lead to material accumulation, and too large inclination will shorten the
screening time.
Frequent screen damage is mainly caused by inconsistent screen material or
improper installation. Due to high hardness of quartz sand, wear-resistant
screen made of high manganese steel or polyurethane shall be selected; During
installation, ensure that the screen tension is appropriate and the edge is
closely attached to the screen frame to avoid friction and damage between the
screen and the screen frame due to looseness.
The abnormal vibration of equipment (such as shaking and abnormal sound of
machine body) is mainly caused by insecure foundation fixation or imbalance of
vibrating motor. Check whether the foundation bolts of the equipment are loose
and fasten them in time; If the eccentric blocks on one side of the vibration
motor fall off, reinstall and adjust the balance to ensure that the angles of
the eccentric blocks on both sides are the same.
4、 Magnetic separation equipment: how to deal with poor impurity removal
effect, roller clamping stagnation and insufficient magnetic field strength?
Magnetic separation equipment (electromagnetic dry powder magnetic separator,
etc.) is used to remove magnetic impurities in quartz sand. Problems directly
affect the purity of finished products.
Poor impurity removal (excessive residual magnetic impurities) may be caused
by insufficient magnetic field strength, too fast rotating speed of roller or
uneven feeding. Gauss meter shall be used to detect the magnetic field
intensity. If the magnetic field intensity is lower than the standard (such as
the magnetic field intensity required for quartz sand purification ≥ 1800
Gauss), the electromagnetic coil shall be checked for aging and the coil shall
be replaced in time; It is suggested to control the rotating speed of the roller
within 10-15r/min. Too fast rotating speed will cause the magnetic impurities to
be thrown out when they are absorbed in the future; During feeding, the
vibrating feeder shall be used for uniform material distribution, so as to avoid
too thick material accumulation affecting the adsorption effect.
The roller is blocked due to bearing failure or material blockage.
Disassemble the roller to check the bearing. If the bearing is rusted or worn,
replace the bearing and apply lubricating grease; If there are large impurities
between the roller and the magnetic system, shut down the machine for cleaning,
and install a impurity removal device at the feed inlet.
Magnetic field intensity instability is usually associated with supply
voltage fluctuations or poor heat dissipation of the field coils. It is
suggested to equip the magnetic separator with voltage regulator to ensure
stable voltage; If the magnetic field is weakened due to the heating of coil,
check whether the cooling system (such as oil cooling device) works normally and
clean the dust in the heat dissipation channel to ensure the heat dissipation
effect.
5、 Daily maintenance of equipment: core points to reduce faults
Most equipment problems are caused by improper maintenance. Good daily
maintenance can greatly reduce the failure frequency: first, regular
lubrication. Bearings and eccentric shafts of crusher and sand-making machine
shall be supplemented with grease periodically to avoid dry friction; The second
is the management of vulnerable parts. Establish the inventory account of
vulnerable parts (liner plate, impact block, screen, etc.), and prepare the
goods in advance according to the wear law; The third is cleaning and
maintenance. After the production of each shift, clean the material residues on
the surface and inside of the equipment, especially the screen of the screening
equipment and the impeller channel of the sand-making machine; The fourth is
regular inspection, weekly inspection of equipment bolt fastening, motor
temperature and operating parameters, making records, and timely handling in
case of any abnormality.
As a professional manufacturer of quartz sand production equipment, we not
only provide single-machine and production line equipment with reliable
performance, but also provide full-cycle technical support for customers. If you
encounter problems not mentioned above in the use of the equipment, please
contact our technical team at any time. We will help you quickly resume
production through remote guidance or on-site service. At the same time, we can
also provide customized maintenance programs according to your equipment use
conditions to extend the service life of the equipment and improve the
production efficiency.