Overflow Screw Conveyor: Characteristics, Core Advantages and Applications
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The core characteristic of the overflow screw conveyor is its open-top trough design. Unlike closed screw conveyors, when the feed rate exceeds the rated capacity, excess materials can naturally “overflow” and be discharged without shutting down the machine. Meanwhile, it is suitable for handling complex materials such as high-humidity and viscous substances. It features a compact structure and easy observability.
Overflow Screw Conveyor: Characteristics, Core Advantages and Applications
I. Core Characteristics
Taking “open trough + overflow discharge” as the core design, it is different from traditional closed screw conveyors:
• The top of the trough is unobstructed. When the feed rate exceeds the rated value, excess materials can naturally “overflow” and be discharged without the need to shut down the machine for adjustment.
• It is suitable for high-moisture,high-viscosity,impurity-containing,or medium-low temperature(≤250℃)materials,which are less likely to adhere and leave residues.
• The machine has a compact structure without complex enclosed shells, making it convenient to observe the material conveying status and suitable for narrow spaces(such as workshop mezzanines and equipment gaps).
II. Core Advantages
• Overload anti-clogging and adaptability to feed rate fluctuations
When the feed rate suddenly increases(such as in the intermittent feeding of coal washing plants and mixing stations),excess materials are discharged through the top overflow.This fundamentally avoids the problems of“material blockage and machine jamming”in ordinary screw conveyors and“material spillage and belt deviation”in belt conveyors.There is no need for manual monitoring and adjustment.
• Strong material adaptability and coverage of complex working conditions
It can stably convey“difficult-to-handle materials”such as wet coal slime,dewatered sludge(with a moisture content of 70%-85%),sand and gravel slurry,and hot slag:The open structure reduces the adhesion and residue of materials in the trough.High-temperature materials can also dissipate heat through overflow to prevent the trough from overheating and getting damaged.In contrast,ordinary screws are prone to“clogging blades”due to viscous materials,and scraper conveyors are prone to“scraper jamming”due to impurities.
• Easy maintenance and reduced maintenance costs
There is no need to disassemble the entire machine(such as the end cover and flange of ordinary screws)to clean residual materials or inspect spiral blades directly from the open trough.There are no complex seals(such as the shaft end seals of closed screws),reducing the frequency of seal wear and replacement.Maintenance costs are 15%-30%lower than those of closed screw conveyors and more than 20%lower than those of belt conveyors(which require frequent alignment and roller replacement).
• Stable conveying and low slippage rate
The gap between the spiral blade and the trough is only 5-10mm.The“slippage rate”during material conveying is less than 3%,which is much lower than that of belt conveyors(the slippage rate of wet and slippery materials can reach 10%-15%).At the same time,the overflow design automatically balances feed rate fluctuations,avoiding“material interruption”or“overloading.”The stability of conveying efficiency is improved by more than 40%.
• Cost-effective and high cost-performance ratio
The manufacturing cost is 15%-30%lower than that of closed screw conveyors(no processing cost for enclosed shells)and 25%-40%lower than that of scraper conveyors(which require supporting drive motors and chain tensioning devices).There is no need to additionally configure “blockage detection devices” and “return cleaning devices,” reducing both initial investment and later maintenance costs.
III. Typical Application Scenarios
• Coal Industry
• Materials: Wet coal slime, gangue slurry, and middlings after coal washing in coal washing plants.
• Value: It can cope with the intermittent feeding fluctuations in the coal washing process, avoid wet coal slime blockage, and the open structure is easy to clean residues and reduce equipment corrosion.
• Environmental Protection Industry
• Materials: Dewatered sludge(with a moisture content of 70%-85%)from sewage treatment plants, slag from waste-to-energy plants, and residues from kitchen waste pre-treatment.
• Value: It is resistant to the viscosity of sludge, easy to clean without residues, and meets the environmental protection equipment requirements of “low pollution and easy maintenance.” The slag can also dissipate heat through overflow.
• Building Materials Industry
• Materials: Sand and gravel slurry, wet fly ash, and concrete waste in mixing stations.
• Value: The sand and gravel slurry can discharge excess water through overflow to avoid “uneven moisture content” in the batching process. The open trough can be directly washed to reduce cement clumping residues and ensure the batching accuracy of the mixing station.
• Agriculture and Grain Processing
• Materials: Wet paddy, corn(with a moisture content of more than 18%), distillers' grains, and bean dregs in feed mills.
• Value: The open structure facilitates the observation of grain quality and prevents wet grain from molding. Cleaning residual feed can reduce microbial growth and meet food-grade hygiene requirements.
• Chemical and Metallurgical Industries
• Materials: Wet filter cakes(such as fertilizer filter residues),metallurgical iron oxide slag, and non-corrosive electrolytic aluminum waste.
• Value: It can withstand medium-low temperature materials. The overflow design shortens the residence time of corrosive materials in the trough, reducing the corrosion rate of the equipment. Ordinary carbon steel material can meet basic needs(304/316L stainless steel is required for strong corrosion).
IV. Precautions for Selection
• It is not suitable for fine powder materials(such as flour and cement powder),as the open structure can easily lead to dust diffusion(additional dust covers are required).
• The conveying angle is limited to horizontal or small-angle inclination(≤15°).If the angle is too large,there will be too much material overflow,and the conveying efficiency will drop sharply.
• For strongly corrosive materials(such as strong acids and alkalis),customized plastic-lined or stainless steel troughs are required to prevent equipment rusting.
Overflow Screw Conveyor,Screw Conveyor,auger conveyor
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