The mixing bucket is a key equipment in the quartz sand washing and
purification process, responsible for thoroughly mixing sand particles with
water (or chemicals) (with a required mixing uniformity of ≥ 95%), providing
conditions for subsequent grading and impurity removal. If there is uneven
mixing (local materials not mixed, insufficient reaction of reagents), severe
scaling on the barrel wall (scale layer thickness exceeding 15mm), it will lead
to a decrease in purification efficiency and a reduction in effective volume.
Based on practical experience, summarize the three-step troubleshooting method
to quickly restore stable mixing performance.
Step 1: Optimize the mixing structure and blade design - the core components
determine the mixing effect
Improper blade shape and installation position are the main causes of uneven
mixing.
Inappropriate blade type or angle: using straight blades to mix coarse sand
(>2mm), insufficient propulsion force, and easy material deposition; The
blade angle deviation exceeds 10 ° (standard 30 ° -45 °), causing the water flow
to form eddies and local mixing dead corners. Replace the "propeller blades"
(suitable for mixing coarse and fine sand), calibrate the blade angle to 35 °
-40 °, and enhance radial thrust; Install 3-4 guide plates on the barrel wall
(with a height of 1/2 of the barrel body and uniform spacing) to eliminate
vortices and eliminate mixing dead corners.
Blade wear or improper installation height: blade edge wear exceeds 1/3 of
the original thickness, and the mixing force decreases; The installation height
is too high (>20cm from the bottom of the bucket), and the bottom material
cannot be driven. Replace the high chromium alloy blades and ensure that the
blades are 5-10cm away from the bottom of the bucket during installation. At the
same time, check the gap between the blades and the bucket wall (maintain
8-12mm) to avoid friction and scaling layers.
Step 2: Calibrate operating parameters and mixing mode - parameter matching
to improve efficiency
Abnormal stirring speed, running time, and feeding sequence can exacerbate
unevenness and scaling.
Speed too fast or too slow: When the speed exceeds 60r/min, energy
consumption increases and materials splash; Below 30r/min, the mixing time is
prolonged (even after more than 30 minutes, it is still not uniform). Use a
tachometer to detect and adjust to 40-50r/min, and achieve stepless speed
regulation through a frequency converter; According to the dynamic adjustment of
material quantity, when the material volume in the bucket reaches 70% -80%,
increase the speed appropriately (50r/min) to avoid low liquid level idling.
Improper running time or feeding sequence: less than 15 minutes of stirring
time, insufficient reaction between the reagent and sand particles; Add the
medicine first and then sand, as the medicine is prone to adhere to the barrel
wall and form scale. Set the stirring time to 20-25 minutes, using the sequence
of "adding sand first → adding water and stirring for 5 minutes → adding
chemicals → stirring for another 15 minutes"; Install a liquid level sensor that
automatically shuts down when the material is below one-third of the barrel to
avoid dry mixing and scaling.
Step 3: Adapt material characteristics and anti scaling measures - avoid
faults at the source
Improper moisture content, mud content, and barrel protection of materials
can accelerate scaling and unevenness.
High mud content or large fluctuations in moisture content of materials: if
the mud content exceeds 15%, the mud powder is prone to adhere to the barrel
wall and blades; If the moisture content is below 30%, the material is in a dry
sand state and cannot be effectively mixed. Add a pre washing process before
mixing to reduce the mud content to below 8%; Accurately control the moisture
content to 40% -50% through a water valve, and install an online moisture
detector for real-time feedback adjustment.
Lack of bucket material or anti scaling treatment: Ordinary carbon steel
buckets are prone to rusting and scaling; Without anti sticking treatment, the
mixture of fine sand and chemicals adheres and accumulates. Apply polyurethane
anti sticking coating (thickness 5-8mm) to the inner wall of the barrel to
reduce material adhesion; Activate the 'empty bucket cleaning mode' every week,
using a high-pressure water gun (0.6MPa) combined with a descaling agent (citric
acid solution, concentration 5%) to rinse the bucket wall and remove initial
scaling.
Daily maintenance should pay attention to: checking blade wear and bucket
wall scaling every day, and cleaning blade entanglements; Calibrate the speed
and liquid level sensors weekly, and tighten the bolts of the mixing shaft
coupling; Thoroughly clean the scale inside the bucket every month and check the
fixing status of the guide plate. By taking the above measures, the mixing
uniformity can be improved to over 98%, and the scaling cycle can be extended to
over 3 months, ensuring stable and efficient quartz sand washing and
purification processes. If there are still problems, it is recommended to
contact the manufacturer to optimize the mixing structure and match the mixing
parameters with specific material characteristics.