Is there a lot of blockage and material return in the large quartz sand
bucket elevator? Shanlu Heavy Industry's optimization plan solves difficult
problems
The bucket elevator is the core equipment for vertical conveying of
large-scale quartz sand production lines (daily processing capacity ≥ 3000t),
responsible for vertically conveying screened and cleaned quartz sand (particle
size 0.1-50mm) to the silo, ball mill and other processes (requiring conveying
efficiency ≥ 95%, return rate ≤ 5%), directly connecting the front and rear
processes, and ensuring the continuous operation of the production line. In
actual production, problems such as material blockage, severe material return,
and rapid wear of the hopper occur frequently, which not only drag down
production capacity but also increase operation and maintenance costs. Based on
years of experience in the research and development of quartz sand equipment,
Shanlu Heavy Industry has developed targeted optimization plans for equipment
operation pain points, significantly improving equipment stability.
Scenario 1: Frequent blockage of machine base - dual cracking from feeding
and structure
Quartz sand has a high density and strong fluidity, and uneven feeding or
unreasonable machine structure can easily lead to material accumulation and
blockage, especially when dealing with fine sand. Shanlu Heavy Industry
Optimization Plan: Firstly, optimize the feeding control, equipped with a
variable frequency vibration feeder, accurately control the feeding amount at
85% -95% of the rated value, avoid instantaneous overload, and install a
material level monitoring device to automatically warn and slow down before
material blockage; The second is to improve the structure of the machine base,
changing the traditional straight tube machine base to a conical bottom type,
installing a high-frequency vibrator at the bottom, and cooperating with an
inclined guide plate to accelerate material flow and reduce sedimentation; The
third is to reserve a quick cleaning port, equipped with specialized cleaning
tools from Shandong Heavy Industry, which can quickly handle blockages and
shorten downtime.
Scenario 2: High Return Rate - Precise Adaptation of Hopper and Unloading
System
A return rate exceeding 8% will result in resource waste and increased energy
consumption, with the core reasons being improper selection of hoppers and
deviation in discharge angles. Shanlu Heavy Industry's targeted optimization:
using deep arc-shaped wear-resistant hoppers, integrated with high manganese
steel material, the hopper volume is increased by 20%, reducing material
throwing and scattering, while optimizing the hopper spacing to avoid feeding
overlap; Adjust the unloading angle of the head to 15-18 °, and match it with
the customized unloading plate of Shanlu Heavy Industry to extend the material
throwing trajectory and ensure thorough unloading; Install an anti backflow
baffle at the head to prevent the material from falling back due to incomplete
discharge, and control the backflow rate within 3%.
Scenario 3: The hopper wears out quickly and the chain is loose - material
and transmission system upgrade
Quartz sand has strong abrasion resistance, and the service life of ordinary
hoppers is less than 800 hours. Loose chains can easily cause hopper
displacement. Shanlu Heavy Industry's solution: The hopper is made of high
chromium alloy composite material, with a ceramic wear-resistant coating sprayed
on the surface, which increases the wear resistance by three times and extends
the service life to over 2000 hours; The transmission chain is made of
high-strength alloy steel chain, equipped with an automatic tensioning device to
compensate for the chain tension in real time, maintain stable tension, and
avoid hopper shaking and deviation; Optimize the drive system by using a
variable frequency speed regulating motor to adjust the speed (25-35r/min)
according to the material characteristics, balancing the conveying efficiency
and wear and tear.
Scenario 4: Poor sealing and dust pollution - Optimization of environmentally
friendly sealing structure
Quartz sand fine powder is prone to dust leakage and does not meet
environmental protection requirements. Shanlu Heavy Industry starts with the
sealing structure and adopts a dual protection of "labyrinth seal+oil seal".
Rubber gaskets are installed at the connection of the casing, with a protection
level of IP65, effectively blocking dust leakage; Installing pulse dust removal
interfaces at the head and tail can directly connect to the dust removal system
of the production line, reducing dust pollution; The casing adopts an integral
welding structure to reduce gaps, while reserving maintenance windows for easy
daily maintenance, balancing environmental protection and practicality.
Through the optimization plan of Shanlu Heavy Industry, three core effects
can be achieved: reducing the material blockage shutdown rate by more than 80%,
and controlling the monthly average shutdown frequency within 1 time; The return
rate remains stable below 3%, and the resource utilization rate has
significantly improved; The service life of the hopper and chain is extended by
2-3 times, and the maintenance cost is reduced by 40%. This solution has been
applied in multiple large-scale quartz sand production lines, adapting to the
transportation needs of quartz sand with different particle sizes, and has been
widely recognized.
If you need to customize optimization plans based on the actual working
conditions of the production line, you can contact Manager Zhang at 13583776655
on WeChat. Shanlu Heavy Industry provides one-stop services from equipment
selection, optimization and transformation to after-sales maintenance to help
quartz sand enterprises improve production efficiency.