High Speed Intensive Mixer for Mixing Clay and All Other Material

• Status: Solid Catalyst
• Response Type: Dehydrogenation
• Classification: Homogeneous Catalysts
• Usage: Positive Catalyst
• Effect Size: Promoter Catalysts
• Manufacturing Method: Mechanical Mixing
• Model NO.: R19
• Application Industry: Industry
• Transport Package: Wooden Box
• Specification: customized
• Trademark: Weida
• Origin: Hunan China
• Production Capacity: 1000L/Day

Product Description

Technology proposal
2.1:
 Preliminary planning of project
One production line of yearly output automotive catalyst substrate 360,000L, include equipments operator training, exclude substrate formula.
291,498,24,291,700(22),2.
yearly output 291,498 pcs, monthly capacity is 24,291pcs, daily capacity 1104pcs(monthly working days based on 22 days), every day working 2 shift(16Hours).

2.2
Technology proposal introduction
2.2.1
Production technology process
Raw material analysis                               Additive  
Raw material batching      Material drying Mixing       Kneading       Material aging
Material extrusion      Material filtering       Material aging        De-airing pugging
Microwave drying      Hot air drying      Auto cutting machine      Semi-product inspection
Final product inspection        Firing

2-1    
Chart 2-1 Catalyst substrate production technology process


,.
III .Equipment selection and parameters
3.1 Equipment selection principle Production line in high automatic and intelligence, production process is simplification, meet environment protection requirements.  Use good inspection equipments, the inspection process during catalyst production is very important, and the performance of inspection equipments is the key of inspection, thus must keep inspection equipment reach high standard. Economic and energy saving, economic principle means select machine in good price with high quality and performance. Energy saving as the important principle of selects equipments, it should select the equipment with lower energy consumption to reduce fuel and electricity uses, at the same time reduce the production cost.

3.2 Equipment list

3.2

S/N	NAME	MODE	QTY	UNIT	REMARK
Substrate manufacturing equipments
1	Raw material automatic metering system	KD2017-206-JX020-001	1	Set	Option
2	Intensive mixer	R19	1	Set
3	Kneader	LGNH-1500L	1	Set
4	De-airing extruder	TCJ1260	2	Set	11 One for pugging one for filtering
5	De-airing extruder	TCJ300	1	Set
6	Auto cutting machine	WDQ-16	1	Set
7	De-airing oil cylinder vertical extruder	YW250	1	Set	Die commissioning purpose
8	Microwave dryer	WLKJ-A80	1	Line
9	drying furnace with the heat air	30m3	1	Set
10	Manual cutting machine		2	Set
11	Auto flue blower		1	Set
12	Light transmittance detector		2	Set
13	Shuttle kiln	20m3	1	Set
Substrate lab equipments
1	Thermal dilatometer	PCY1400	1
2	Compressive strength tester	SGW-5T	1
3	Isostatic pressing machine	JYY	1
4	Chemical analysis unit	GKF-V	1
5	Water absorption meter	TXY	1

3.3 Machine technical Parameters
Substrate manufacturing equipments
3.3.1  Raw material auto batching system

S/N	Item	Specification	Unit	Qty
101	9.5m³ Silo 9.5m³	Φ2000X3000mm	Pcs	6
	Stairs for silo		Lot	1
102	Belt conveyor	KDB500	Line	1
103	Discharger	KDB500	Pcs	1
104	Dynamic measuring belt batching system	1,1, 1,B500/4 Load cell 1 lot, load measuring instrument 1 set, control cabinet 1 set,B500.4 belt 1 line	Set	1
105	Control of electric appliance		Line	1

3.2.2 R19 Intensive mixer
Capacity: 900/ 900kg/batch
Main shaft rotation speed:750RPM(, adjustable)
Plate rotation speed:10/
Diameter:19000mm
Motor power:110.6KW
Mixing time:,according technology prescribe
Overall size:3700×2500×2640mm
Weight:13000Kg()
Power supply requirement: 3φ×380V×50Hz
Control : 1φ×220V×50Hz and DC24V ()



3.2.3,LGNH-500L
Screw extrusion type kneader
 

Volume	500L
Effective mixing volume	500L
Main Motor Power	15KW-4P
Screw Motor Power	12.5KW-4P
Discharge type	Screw extrusion
Cylinder structure	W,. W shape cylinder, jacket structure
Cylinder material
: Machine touch raw material	SUS304 All is SU304 stainless steel
Inner cylinder	12mmSUS304 12mm SU304 stainless steel
Outer cylinder	12mmQ235B 12mm SU304 stainless steel
Mixing speed	fast shaft 38r/min slow shaft 24r/min
Shaft diamter	φ200mm
De-airing degree	≤-0.092Mpa

3.2.4,TCJ1260 Pug mill
Motor Power: 22KW()
Screw blade diameter: Φ180mm
Mixing shaft rotation speed:22Rpm
Extrusion screw diameter:Φ260mm
Extrusion shaft material: 40Cr
Capacity:5T/H
Vacuum degree:-0.095Mpa
Overall size: 4730×1130×890mm
Net Weight: 3000Kg

3.2.5,LCJW-250 De-airing extruder
Horizontal pug mill part:
,
There are guide rails between the horizontal part and the platform, which can be moved as a whole
: 30KW-4P-55.76
Horizontal mud training reduction motor: 30KW-4P-55.76
:26r/min()
Clay shaft rotation speed: 26r/min (adjustable)
:2*Φ180mm
Clay spiral: 2*Φ180mm

Clay mud tube with water cooling
,
The horizontal pug mill part has a split mud cylinder and is equipped with movable guide rails for easy disassembly and cleaning.
:Horizontal extrusion part:
:26/()
Horizontal extrusion main screw speed: 26 rpm (adjustable)
:Φ260mm
Horizontal extrusion main screw diameter: Φ260mm
:20/()
Horizontal extrusion auxiliary screw speed: 20 rpm (adjustable)
:Φ180mm
Horizontal extrusion auxiliary screw diameter: Φ180mm
:≤15MPa
Horizontal extrusion maximum pressure: ≤15MPa
: 55KW-4P-56.99
Horizontal extrusion reduction motor: 55KW-4P-56.99
,
Temperature and pressure display, installed in the connection position with the vertical part
≤-0.094MPa
Vacuum degree≤-0.094MPa
,,
Horizontal extrusion mud cylinder, vacuum chamber, main spiral with water cooling
:Vertical extrusion part:
: 75KW-6P-
Reducer: 75KW-6P-
:Φ250mm
Extrusion screw diameter: Φ250mm

The spiral adopts variable diameter and variable pitch screw
:9.6/()
Vertical extrusion speed: 9.6 rpm (adjustable)
18MPa
The maximum pressure in front of the vertical extrusion screen is 18MPa
:≤150
Vertical extrusion screening capacity: ≤150 mesh screen
()
Temperature and pressure display (one set at the front and rear of the screen)
:≤500mm/()
Extrusion speed: ≤500mm/min (different product specifications correspond to different extrusion speeds)
:1450mm()
Height from mold outlet to ground: about 1450mm (can be customized according to customer requirements)
:8700*4400*3650()
Platform size: 8700*4400*3650 mm (can be adjusted according to customer requirements)


3.2.6, Vertical oil cylinder extruder
Extrusion pressure:25T
Main oil cylinder stoke: 660mm
Main oil cylinder speed: stable speed 0.1-0.96m/MIN
Material cylinder diameter and length: 160*550mm
Material cylinder rotation angle: 0-54°
Oil volume:  150L
Motor Power:75KW
Overall size(L×W×H): 2320*750*1650


3.2.7 Micro wave dryer

S/N	Item	80kW 80kW continuous micro wave dryer fast drying furnace
1	Model	WLKJ-A80
2	() Overall size (about)	16000mm*1250mm*2400mm(** L×W×H)
3	Power supply	3 phase 5 line 380V±10% 50Hz±1%
4	Rated power input	≤120KVA( about)
5	Rated power output	≤80kW( 80kW Max. output 80kW)
6	Micro wave frequency	2450MHz
7	Micro wave reclaiming energy	hexagon with 5 side reclaiming energy
8	Product allowed	Height≤200mm,Diameter ≤150mm Substrate
9	Capacity	≤80KG/ Quantity of delivery water ≤80KG/H
10	Working environment	:-5~45ºC :≤80% Environment temperature :-5~45ºC Relative humidity:≤80%
11	Drive mode	2450MHz SUSUNG EXPORTED 2450MHz micro wave driver
12	transporting manner	, 0.5m/min~5m/min . Adopt stainless steel chain delivery, delivery speed 0.5m/min~5m/min(adjustalbe)
13	Control mode	PLC+10″ PLC+10″LCD touch screen
14	Micro wave leakage	:GB 5959.6-2008 China: GB 5959.6-2008 micro wave leakage national standard
15	Electricity safety	GB 5226.1-2002 China: GB 5226.1-2002 machine and electricity safety national standard
16	Measuring device	1 .( Omega ) Chose a most valuable inspection position to install a Omega Temperature probe

3.2.8 Manual cutting machine
Motor Power:6.5KW
Length allowed :80-400mm
Diameter allowed:100-385mm
Cutting accuracy: 0.2mm
Overall size(L×W×H):1.5*1.0*1.2m
Net weight: 500Kg

3.2.9 Auto dust collector

,.
  Tunnel type dust collector, adopt forward and backward, multi direction soot blowing
3.2.10 Light transmittance detector
  Pneumatic lift

  Flat light transmittance

3.2.11  20M3 Shuttle kiln
Kiln size:
Inner size:3.84 M *3.18 M *1.635 M(L*W*H,H- H-from kiln car surface to kiln roofing)
Outside size: About 5.0 M *4.5 M *3.2 M(L*W*H)
Volume:about 20.0 M3
Kiln car platform size: about 1.93M*2.98M(L*W)
Kiln car qty inside kiln:2 sets
Kiln car qty:4(2 2 sets for spare outside kiln)
Fuel:
Gas type: Nature gas
Gas thermal value:≥8500 kcal/NM3
Firing Set:
Firing type: flame bare firing
firing atmosphere: oxidizing flame
Firing temperature:<1450ºC
Design temperature:1500ºC
Firing period: about 50-100hr ()
Other related parameters:
Nozzle Qty:6 Pcs
Control group qty:6 groups
Temperature control mode: pulsed automatic control
Temperature inspection qty:7 points
Pressure inspection qty:4points
Smoke exhaust fan motor power :22KW
Combustion fan motor power:18.5 KW
Total motor power:about 47 KW
Weight:About 96T
Ferry car:1 set


Substrate Lab Equipments :
S3.2.1: Thermal dilatometer

Max Temperature allowed:~1400ºC
Heating Rate T0~20ºC/MIN
Temperature difference±1ºC
Distortion inspection range :±5mm
,,,-
  Computer automatic control temperature, recording storage, printing date, printing temperature-thermal expansion rate curve

S3.2.2: Compressive strength tester

Max Loading: 5T
Loading speed:0.5~4MPa/S adjustable
,0.5% Date processed by micro computer, accuracy reach 0.5%

S3.2.3: Isostatic pressure testing machine
Max pressure allowed :16MPa
Testing tolerance: <=1%
rate of pressure increasing:0~0.5MPa/S adjustable
Effective volume:300/300mm Diameter 300/Height 300m

S3.2.4: Chemical analysis instrument

Analysis of the composition of silicate minerals
Tolerance: 0.01%

S3.2.5: water absorption meter

Vacuum degree:0.1±0.005MPa Adjustable
Lab volume:diameter 250*L300mm
Vacuum retention time:0~120MIN continuous adjustable
Water injection time:0~100MINcontinuous adjustable
Soak time:0~100H continuous adjustable