The three return drum dryer is the core equipment in the powder drying
process of large-scale quartz sand production lines (daily processing capacity ≥
3000t), mainly used to reduce the moisture content of quartz sand powder
(particle size 0.074-0.4mm) (required to have a moisture content of ≤ 0.5% after
drying, suitable for subsequent packaging and purification processes). Its
operational stability directly affects the quality, production efficiency, and
energy consumption cost of finished sand. In actual production, most enterprises
encounter problems such as uneven drying, high energy consumption, and sticking
of cylinder materials, which affect the continuous operation of the production
line. Shanlu Heavy Industry is located in Wenshang, Shandong Province. It is a
national high-tech enterprise and a technology-based small and medium-sized
enterprise, specializing in the research and development, manufacturing, and
service of quartz sand production line equipment for more than ten years. It has
rich experience in drying machine optimization and operation and maintenance,
and can provide full process services from equipment selection, standardized
optimization to after-sales support.
1、 Common Problems and Analysis of Compliance Causes
Based on the on-site inspection experience of over a hundred production lines
by the technical team of Shanlu Heavy Industry, the common problems and causes
of the three return drum dryer are mostly related to operating standards and
equipment compatibility, and there is no exaggerated fault cause:
1. Uneven drying: The moisture content of the finished sand fluctuates by
more than 0.3%, and some particles agglomerate. The core causes are uneven
distribution of hot air, large fluctuations in feed volume, and improper
adaptation of cylinder speed, rather than design defects in the equipment
itself; 2. High energy consumption: The unit drying energy consumption exceeds
the industry average by more than 10%, mainly due to low utilization of hot air,
decreased sealing performance, and insufficient fuel combustion; 3. Adhesive
material on the cylinder: Residual powder clumps on the inner wall of the
cylinder are mainly caused by high feed humidity (over 5%), unreasonable
temperature control of the cylinder, and long-term failure to clean.
2、 Shanlu Heavy Industry Standard Optimization Plan (compliant and pragmatic,
implementable)
Shanlu Heavy Industry abandons exaggerated propaganda and develops targeted
optimization plans based on equipment operation principles and on-site practical
experience. All measures comply with industry norms and safety standards, and
does not promise illegal statements such as "ultimate energy consumption" and
"zero failures".
1. Optimize the parameters of hot air and cylinder body to solve the problem
of uneven drying
To address the uneven distribution of hot air, optimize the layout of hot air
ducts, install diversion devices to ensure even distribution of hot air along
the axial direction of the cylinder, and increase the contact area between hot
air and materials; Equipped with a variable frequency feeding system, the
feeding amount is stabilized at 85% -95% of the rated value of the equipment to
avoid insufficient drying caused by instantaneous overload; According to the
moisture content of the feed, the cylinder speed is precisely adjusted to 3-5
r/min to meet the drying requirements of materials with different humidity
levels, so as to control the fluctuation of the moisture content of the finished
product within 0.2%. Shanlu Heavy Industry can provide on-site calibration
services to assist enterprises in debugging the optimal parameters.
2. Improve heat utilization efficiency and reduce energy consumption
losses
Optimize the hot air circulation system and install a waste heat recovery
device at the tail of the cylinder. The recovered waste heat is used to preheat
the feed and improve the utilization rate of hot air; Replace aging seals and
adopt a labyrinth sealing structure to reduce hot air leakage and heat loss; In
response to the problem of insufficient fuel combustion, efficient burners are
equipped to ensure sufficient fuel combustion. At the same time, the supply air
volume is adjusted in real time according to the combustion situation, and the
unit drying energy consumption can be reduced by 8% -12%, reaching an advanced
level in the industry.
3. Standardize operation and cleaning to reduce material sticking to the
cylinder
Clear operating standards require that the moisture content be controlled
below 5% before feeding, and a pre dehydration process should be added when the
humidity is too high; Install a detachable wear-resistant scraper plate on the
inner wall of the cylinder, and clean residual powder in real-time with the
rotation of the cylinder to reduce the accumulation of sticky materials;
Establish a regular cleaning system and recommend stopping the machine once a
week to clean the inner wall of the cylinder, in order to avoid clumping and
residue affecting the drying effect. Shanlu Heavy Industry can provide
operational training and standardize operation and maintenance processes for
enterprises.
3、 Key points for daily compliance operation and maintenance (suggested by
Shanlu Heavy Industry)
1. Monitor the moisture content, cylinder temperature, and energy consumption
data after drying daily, keep operation records, and promptly investigate any
abnormalities found; 2. Check the integrity of seals, wear of scraper plates,
tighten loose parts, and replenish lubricating grease every week; 3. Calibrate
parameters such as hot air flow rate and cylinder speed every month, and clean
the waste heat recovery device and burner; 4. Conduct comprehensive equipment
maintenance every quarter, replace aging components, and ensure long-term stable
operation of the equipment.
Shanlu Heavy Industry has always adhered to the concept of compliance
management, focusing on the research and development of quartz sand equipment
and services. It has more than 1200 service cases and over 800 sets of standard
equipment. The technical team is composed of more than 80 professionals, who can
provide compliant and practical equipment optimization and operation solutions
for enterprises. If your production line is facing problems such as uneven
drying, high energy consumption, and stick material on the drum of the three
return drum dryer, or if you have equipment selection and optimization needs,
please feel free to contact Manager Zhang at 13583776655 or WeChat. Shanlu Heavy
Industry will help enterprises improve production efficiency and reduce
operating costs with professional technology and practical solutions.