Selection Reference for Rotary Feeder and Crusher Accompanying En-masse Conveyor in Coal, Chemical, Grain, and Building Materials Industries
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The core of equipping a En-masse conveyor with a rotary feeder and a crusher is to adapt to the material characteristics, ensure the stability of the conveying process, and meet the process connection requirements.
Reasons for Equipping with a Rotary Feeder
• Accurate Material Control and Congestion Prevention: A En-masse conveyor requires continuous and uniform feeding. A rotary feeder can precisely regulate the material flow rate, preventing the material from piling up all at once, which could cause the conveyor to jam or become overloaded.
• Sealing and Isolation for Safety: It can isolate the pressure difference between the upstream and downstream of the conveyor, preventing dust leakage that could pollute the environment and avoiding air backflow that could affect conveying efficiency. This is particularly suitable for closed-process scenarios.
• Adaptation to Material Forms: For powdery and fine-grained materials that are prone to dusting and have poor fluidity, it can achieve smooth transition feeding, reducing problems such as material bridging and sticking to the walls.
Reasons for Equipping with a Crusher
• Reducing Material Size Threshold: A En-masse conveyor has requirements for the feed size. Large and hard lumps of material can get stuck in the scraper chain or damage the equipment. A crusher can break the material down to a suitable size.
• Ensuring Smooth Conveying: After crushing, the material particles are more uniform, which can reduce bridging and blockage during the conveying process, improving the operating efficiency of the conveyor and reducing equipment wear.
• Connecting Front-end Processes: If the upstream feed is in the form of lumps(such as raw coal or ore), the crusher can complete the pre-treatment of turning“coarse material into fine material,”making the material meet the feed standards of the En-masse conveyor and ensuring the continuity of the process.
Combining the material characteristics(such as particle size, corrosiveness, and moisture content)and working conditions of the coal, chemical, grain, and building materials industries, where En-masse conveyors are frequently used, a selection comparison table for the accompanying rotary feeder and crusher is compiled. Auxiliary equipment that matches the process chain is also supplemented to improve the process. The details are as follows:
Industry | Materials | Selection of Rotary Feeders | Selection of Crushers | Auxiliary Equipment | Selection Notes |
Coal Industry | Raw Coal, Coal Fines, Coal Gangue, Crushed Slag | (1)Material: Wear-resistant alloy steel shell + cemented carbide blades are adopted to cope with the high wear of materials such as coal gangue; (2)Type: High-temperature resistant rotary valve, suitable for working conditions of 100 - 200℃ near the boiler system; (3)Sealing: Double mechanical seal to prevent potential safety hazards caused by coal fines leakage and air backflow. | (1)Primary Crushing: Jaw crusher (handles large lumps of raw coal; the width of the feed inlet is ≥ 1.5 times the particle size of the largest coal lump); (2)Secondary Crushing: Ring hammer crusher (e.g., Model PCH0402) with a discharge particle size ≤ 30mm, which meets the feeding requirements of En-masse conveyors, adapts to the brittle characteristics of coal, and features high crushing efficiency. | (1)Iron Remover: Removes metal impurities from raw coal to avoid scratching the scraper chain; (2)Pulse Dust Collector: Treats coal fines dust generated during crushing and conveying; (3)Level Switch: Prevents conveyor overload caused by coal lump accumulation. | In the coal industry, materials are highly abrasive and prone to dust generation. The core focus of equipment selection lies in wear resistance, sealing, and explosion protection. For crushers, impact-type models suitable for brittle materials are preferred; for feeders, airtightness is enhanced to ensure safety. |
Chemical Industry | Chemical powders (e.g., sodium carbonate, catalysts), corrosive particles (e.g., ammonium chloride), flammable and explosive materials (e.g., chemical intermediates) | (1)Material: For corrosive materials, 316L stainless steel or PTFE-coated shells are selected; for flammable and explosive materials, explosion-proof motor-driven models are adopted; (2)Type: Fully airtight rotary feeder, which isolates upstream and downstream pressure and prevents leakage of toxic/flammable and explosive gases; (3)Control: Frequency conversion speed regulation type, accurately matching the feeding rate of chemical reactions. | (1)Type: Toothed roll crusher or small impact crusher, which avoids high-temperature sparks during the crushing process and is suitable for flammable and explosive materials; (2)Material: The inner wall of the crushing chamber is lined with an anti-corrosion coating to cope with corrosive materials; (3)Specification: Hourly processing capacity of 5 - 20 t/h, adapting to the scale of small and medium-sized chemical production lines. | (1)Explosion-proof Control Cabinet: Linked with feeders and crushers to realize emergency shutdown; (2)Gas Detector: Monitors the concentration of toxic/flammable and explosive gases in real time; (3)Drying Device: Reduces material moisture content to avoid equipment blockage caused by viscous materials. | Most materials in the chemical industry are corrosive, toxic, flammable, or explosive. The core of equipment selection lies in corrosion resistance, explosion protection, and airtightness, and the equipment must be accurately matched with the process reaction rate. |
Grain Industry | Wheat, Corn, Soybeans, Grain Flour, Cake Meal | (1)Material: Food-grade stainless steel is used to avoid grain contamination and meet food safety standards; (2)Type: Lightweight rotary feeder with adjustable speed (5 - 30 r/min) to prevent grain particle breakage; (3)Structure: An additional scraper device is added to avoid grain residue and mildew. | (1)Type: Low-speed toothed roll crusher (e.g., double-roll crusher) with a discharge particle size of 5 - 10 mm, suitable for grain processing needs without excessive crushing; (2)Special Design: The surface of the crushing roll is made of elastic material to reduce oil overflow from oil crops such as soybeans. | (1)Cleaning Screen: Removes impurities such as straw and gravel from grains; (2)Moisture-Proof Device: Controls the humidity of the conveying environment to avoid grain caking; (3)Electrical Interlocking Device: Realizes the linked control of feeding, conveying, and discharging. | The core of equipment selection in the grain industry is to ensure material integrity and food safety. For feeders, emphasis is placed on residue prevention; for crushers, low-damage crushing is the main focus, while moisture and dust prevention are simultaneously strengthened. |
Building Materials Industry | Cement, Sand and Gravel, Lime, Gypsum Powder | (1)Material: High wear-resistant cast iron or alloy wear-resistant steel is adopted to cope with the strong wear of materials such as cement, sand and gravel; (2)Type: Large-caliber rotary feeder (feed inlet ≥ 200mm), suitable for the conveying of small lumpy materials such as sand and gravel, lime; (3)Sealing: Packing seal + gap compensation structure to prevent dust leakage. | (1)Primary Crushing: Jaw crusher (handles large lumps of limestone; feed particle size ≤ 300mm); (2)Secondary Crushing: Impact crusher with a discharge particle size ≤ 10mm, suitable for the fine material requirements such as cement raw meal, and resistant to medium-hard materials like lime (Mohs hardness 4 - 5). | (1)Vibrating Screen: Classifies crushed materials to ensure uniform particle size; (2)Dust Cover: Covers the interfaces of crushers and feeders to reduce dust pollution; (3)Wear-Resistant Liner: Installed in the conveyor trough to extend equipment service life. | In the building materials industry, materials have medium hardness, high abrasiveness, and large dust generation. The core of equipment selection lies in wear resistance and large processing capacity. For crushers, the combination of primary crushing and secondary crushing is emphasized; for feeders, structural strength is enhanced to adapt to large lumpy materials. |
Power Industry (Boiler Auxiliary Equipment) | Fly ash, Boiler slag, Pulverized coal | (1)Material: High-temperature resistant alloy material (300 - 400℃), suitable for high-temperature materials at the boiler tail; (2)Type: Air-locked rotary feeder, preventing air backflow caused by boiler negative pressure to ensure combustion efficiency; (3)Specification: Hourly processing capacity of 30 - 100 t/h, matching the large capacity requirements of power stations. | (1)Type: Ring hammer crusher or hammer crusher, which handles large lumps of boiler slag with a discharge particle size ≤ 20mm and is suitable for the brittle characteristics of fly ash and boiler slag; (2)Design: The gap of the crushing chamber is enlarged to avoid blockage caused by wet boiler slag. | (1)Wear-Resistant Scraper Chain: Adapts to the high abrasiveness of boiler slag and extends the service life of key conveyor components; (2)Frequency Conversion Drive Device: Adjusts the feeding capacity to match the boiler load; (3)Moisture Discharging Device: Reduces the moisture content of boiler slag to prevent caking. | In the power industry, materials are high-temperature, highly abrasive, and have large capacity requirements. Equipment selection focuses on high-temperature resistance, wear resistance, and large flow rate, and the equipment must be linked and adapted to the boiler operating conditions. |
Crusher,Rotary Feeder,En-masse conveyor
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