Introduction to Water-Jacketed En-masse Conveyor
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Introduction to Water-Jacketed En-masse Conveyor
The water-jacketed En-masse conveyor (buried scraper conveyor) integrates functions of materials handling and temperature control. Its configuration is quite straightforward; it simply adds a water jacket on the outside of the trough of a traditional En-masse conveyor. Water circulation allows heating or cooling of the material; it finds application in powdery, granular, or small lumpy materials where temperature control might be warranted, for example, to cool high-temperature slag or to convey low-temperature materials at a constant temperature.
Ⅰ. Core Functions and Application Scenarios
It has core values in two needs: 'material conveying' and 'temperature control,' which offer solutions in preventing adverse temperature conditions from impacting the materials during conveying, such as high-temperature caking or low-temperature freezing.
Other applications may involve:
In the chemical industry: Conveying high-temperature reaction materials which require cooling and materials possessing a solidifying property, for which insulation is needed.
In the metallurgical industry: Cooling and conveying high-temperature furnace slag and dust.
In the food industry: Conveying granular raw materials with constant temperature during their transportation, sugar, or grains.
Ⅱ. Key Structural Components
The following are additional or optimized components that allow perfect coordination between temperature and material transportation:
Water jacket system: The outer part is provided with an arrangement of directing water flow- generally baffles- inside the water jacket, which is the main element that performs the function of temperature control.
Sealing Structure: This comprises welding equipment that seals at the junction between the jacket and the trough and dynamic seals at shaft ends, usually a combination of mechanical and oil seals, preventing water and materials from leaking.
Temperature control auxiliary components: These are pressure gauges, thermometers, and safety valves at the jacket inlet and outlet, with an auxiliary water circulation system, such as a constant-temperature water tank and heat exchanger, ensuring stable water temperature and pressure.
III. Key Design and Use Considerations
The water jacket En-masse conveyor is designed to work continuously without any interruption in the conveyer system while controlling the temperature of the conveyed material. This requires a careful balance among three leading design considerations: the heat exchange efficiency of the water jacket, the reliability of the seals, and their compatibility with the conveying mechanism.
1. Water jacket heat exchanger system design
It is a core element in achieving material temperature control, either heating or cooling, and it directly determines the temperature control result.
Optimization of heat exchange structure: The jacket should then cover the trough's key temperature control sections. It would be advisable to have baffle plates or, alternatively, spiral flow guides installed to prevent water from shortcutting to ensure uniform water flow over the trough wall, thus increasing the heat exchange efficiency.
Selection of materials: Based on both the corrosive nature of the material and the water temperature, 304/316L stainless steel is appropriate when conveying corrosive materials. If water temperatures exceed 100 °C, materials with high-temperature strength should be selected to avoid deformation due to long-term use.
Parameter safety control: Pressure gauges, thermometers, and safety valves shall be provided at the jacket inlet and outlet to prevent water pressure from rising suddenly. Since an appropriate water circulation system, such as a constant-temperature water tank, is provided along with the stable water temperature at the inlet, this does not pose any problem.
2. Sealing and Protection Against Leakage Design
Any seal failure could cause equipment malfunction; therefore, two main seals must be emphasized.
Welding seal between the jacket and the trough: Use double-sided welding or TIG welding. After welding, conduct a hydrostatic test at a test pressure of 1.25-1.5 times the working pressure, holding it for more than 30 minutes to check for leaks in the welds.
Dynamic seal at the shaft ends: Water ingress and material leakage prevention at head and tail shaft ends. It consists of "Mechanical seals+skeleton oil seals," or one can opt for a suitable corrosion-resistant double-lip oil seal to the bearing housing to prevent water ingress.
3. Compatibility with the conveying system
It should not interfere with the normal operation of the scraper in terms structure and function.
The jacket occupies some internal space in the trough; hence, effective cross-sectional area calculations will need to be recast to allow for 5-10mm clearance between the scraper and the trough side walls and bottom to avoid friction, jamming, or material residue.
The additional weight of the jacket, along with the possible change in material condition after temperature control, necessitates the recalculation of operating resistance when the material may soften and become sticky. The selection of scrapers will be of higher strength, such as Mn13 wear-resistant steel, matched with sufficiently powerful drive motors.
4. Installation and maintenance convenience
Additional requirements will be installation and maintenance convenience. The design should consider reducing subsequent maintenance costs, while complex structures will be avoided that make inspection and repair difficult.
Maintenance interface reservation: The lowest point of the jacket will be interfaced with a flange to facilitate scale cleaning. Inlet and outlet pipelines will also have flange interfaces for easy disassembly and cleaning.
External protection design: If the equipment is used outdoors or in a dusty environment, an external protective cover should be added to the jacket to prevent impact deformation and dust accumulation that can affect heat dissipation.
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