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Correct use of pellet feed processing equipment
In order to ensure the pellet feed processing equipment operates efficiently, extends its service life, reduces malfunctions, and enhances economic returns, the author has compiled several practical recommendations for reference.
1. **Installation and Commissioning of Equipment**
Before installation, it is essential to verify that the layout and foundation plan match the design specifications. Any discrepancies must be corrected before proceeding with installation. The installation team should thoroughly understand the technical requirements of each piece of equipment and strictly follow the guidelines during setup. It’s also important to inspect the equipment for any damage or missing parts that may have occurred during transportation. Each unit should be labeled and installed in a sequence that follows the process flow chart. The installation order should start from top to bottom, beginning with the main machine and frame, followed by connecting pipes and electrical components. All necessary tools and materials must be available prior to starting. After installation, rotating parts should move smoothly without any jamming or unusual noises, and all connections should be secure and leak-free. Electrical installations must comply with national regulations, ensuring clear wiring and no risk of electric shock or rodent damage. Once all equipment is installed, each system should undergo an empty run test before being subjected to a load test. The electronic batching and packing scales must be calibrated to meet accuracy standards before the load test begins. A continuous 8-hour test run without faults is required before the system can be handed over for production.
2. **Operation and Use**
Before operation, on-duty personnel should inspect the equipment for foreign objects, check the flexibility of moving parts, and ensure all connections are tight and free from leaks. Lubrication levels in gears, belt tension, and the condition of critical parts like crusher hammers, granulator dies, and press rollers should be checked. The control room staff should manage daily production schedules and material storage to ensure smooth operations. The startup sequence should begin with the main power switch, followed by activating each system in order. An alarm signal should be sounded to notify workers. Once everything is ready, the control room staff will determine the material in-warehouse numbers and activate the dust removal fan first, then proceed with the processing sequence. The raw material system starts with the dust fan, then the crusher, conveyor, and so on. The secondary material system and batch mixing system follow similar procedures, with the latter offering both manual and automatic control options. The pelletizing system is controlled via a dedicated cabinet. Control room operators must monitor the simulation screen continuously and respond promptly to any signals, such as full or empty ingredient bins. Operators must input the correct formulas into the computer and manage auxiliary devices accordingly. Feeding devices should be operated carefully to avoid clogging, and trace elements and vitamins should be added at the right time.
3. **Maintenance and Repair**
Regular maintenance is crucial for optimal performance. Bearings should be lubricated with ZG-3 calcium base grease, while reducers use HJ-60 oil, switching to HJ-20 in colder conditions. Equipment should be inspected every six months and fully overhauled annually, including lubricant replacement and part repairs. Belt tension should be adjusted regularly to prevent slippage. Worn-out components like hammers, screens, and pressure rolls must be replaced based on productivity or product quality. When replacing hammers, their weight differences must not exceed 5 grams, and they should be arranged according to the diagram. Electronic scales should be recalibrated after six months of use, and the granulator cavity should be cleaned after each shift. The control room should remain clean and quiet for efficient monitoring.
4. **Common Faults and Troubleshooting**
Excessive vibration in the crusher could indicate improper hammer arrangement, worn hammers, or bearing issues. The return of ash to the feeding port may result from overfeeding or clogged screens, requiring immediate cleaning. Unusual noise often indicates foreign objects in the crushing chamber, which should be removed. Coarse particles may arise from damaged or improperly installed screens. Poor mixer performance might be due to broken belts, and excessive dust could stem from loose seals or worn ducts. Motor overheating or weak performance may signal electrical issues or overload, necessitating inspection or workload adjustment. If the particle machine fails to discharge, blockages in the feed inlet or mold holes, moisture content imbalances, or incorrect die-to-roll clearance could be the cause. Signal failures on the analog screen may be due to faulty sensors, wiring issues, or broken lamps. A significant drop in productivity could be caused by worn hammers, blocked screens, or insufficient steam supply. Adjustments and inspections are essential to maintain efficiency and reliability.