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The design of this sandblasting room project follows the following principles:
Strictly implement relevant national industry standards and general technical specifications;
2. All the selected technologies are mature and reliable ones that have been successfully applied and contain no experimental elements.
3. The design meets the actual production process requirements of customers;
4. Based on our company's many years of professional experience and the structural characteristics of the workpieces themselves, with the aim of meeting the needs of users, the design and production focus on the stability, safety, environmental protection and energy conservation of the equipment.
5. People-oriented, fully considering the actual operation of the operators and maintenance personnel, and comprehensively taking into account the stability of the equipment and the convenience of maintenance and repair.
Main features
1. No need for deep pits, saving infrastructure costs;
2. The sand material recovery and circulation method without transmission conveying machinery is adopted, which has a low failure rate and requires no maintenance. Reduce downtime for maintenance and minimize the losses caused by such downtime.
3. Simplify the structure. Interlock control is adopted for the control of each system to enhance the convenience and speed of equipment maintenance and repair.
4. Standard modules for key worn parts are provided, which are convenient for maintenance and replacement, avoiding heavy inspection and maintenance work.
5. The sandblasting chamber body adopts a dust suppression circulation method of air intake from the top and air suction from the bottom. The dust is always drained downward, the visibility inside the chamber is high, the working environment for employees is good, and both the quality and efficiency of sandblasting operations are guaranteed. At the same time, it protects the physical and mental health of workers;
6. The integral sand-absorbing floor can recover all the sand in an instant, leaving no residual sand on the ground. The indoor site of the sandblasting room is clean and tidy, eliminating the need for manual cleaning and saving working time. The abrasive recovery rate of the pneumatic pipeline is as high as 99%, which is convenient for abrasive replacement. It is almost impossible to thoroughly clean and replace the abrasive in traditional mechanical recycling (or sandblasting floor) sandblasting rooms.
7. The overall technical performance of the sandblasting room is advanced, and the dust emission meets and is lower than the national and local environmental protection requirements, completely eliminating environmental pollution.
Main technical parameters
1.The external dimensions of the sandblasting room: Customizable
The dimensions of the workpiece entry and exit gate are: 2.2(L)*2(W)m
2. One set of sandblasting mainframe
The diameter of the sandblasting tank is 700mm
The volume of the sandblasting tank: 0.4m ³
Number of spray guns: 1
Nozzle diameter: φ10mm
Single-gun cleaning speed: 15m ² /h
Single gun air consumption: 7m ³ /min
3. Sand material type: brown corundum.
The application range of sand particle size is 0.2 to 1.2mm
Initial addition amount: 300kg(brown corundum)
4 Surface cleaning grade: Sa2.5(GB8923-88)
5. Workpiece conveying method: Manual crane hoisting and turntable track entry
6. 6 Lighting system: 1 set
Lighting lamp type: LED lighting lamp
Number of lighting fixtures: 4
Lighting power: 4*50(W)=200W
7. Sand and dust separator: 1 set
Sand and dust separation method: Two-stage separation
Separation particle size: 40 mesh
Separation capacity: 2T/h
8 Sand material recovery system
Processing air volume: 6000m ³ /h
Filtration method: Filter element filtration
Power: 30kw
9 Dust emission: < 50mg/m ³
10 Noise: < 85B(d)
11 Illumination: ≥300lux
12 Sandblasting suits: 1 set
Sand recovery system (local sand return)
The bottom of the sandblasting room is the area for collecting sand and laying out dust suction pipelines, which is specifically used to collect the abrasive scattered during sandblasting and the dust generated during the sandblasting process. This plan uses steel plates to make the sand collection area into a sealed inverted "V" shape, which is conducive to the recovery and capture of abrasives and dust.
The modular combination of the sandblasting room and the detachable honeycomb floor has been optimized and improved multiple times, and the wear and maintenance of the honeycomb recycled floor and recycling pipes during long-term use have been fully considered. The recycled floor and recycling pipes have been made into a modular combination method that can be disassembled and assembled. It makes the maintenance work of the equipment extremely simple and fast, saves a large amount of parts replacement, and reduces the maintenance cost of the equipment during long-term use. For sandblasting rooms of this type of structure, it is only necessary to make the trench depth 0.65 meters.
The bottom of the honeycomb floor is evenly covered with small honeycomb-shaped hoppers, which are connected to the air distribution pipelines beneath them. The wind speeds of both the air distribution pipelines and the main air pipelines are greater than the suspension speed of the sand material. During the sandblasting operation, all the sand sprayed out falls into the small honeycomb-shaped buckets, then into the air distribution pipes, and finally returns to the sand and dust separator through the main air pipeline.
Honeycomb recycled flooring has relatively quick and simple maintenance methods. Firstly, the structure of honeycomb flooring is simple, with few easily worn parts and fewer parts that require maintenance. Moreover, the honeycomb floor adopts a modular combination method, which can conveniently disassemble each part and enter the maintenance point. Then, the honeycomb floor made the easily worn elbow pipes and other components into "standard parts", that is, standard replacement accessories, which were connected by flange interfaces. When replacing, just open the bucket plate, loosen the interface, take out the worn parts and replace them with new parts. There is no need to weld or cut on site. It greatly facilitates daily maintenance and repair.
Sand and dust separation system
To ensure the quality and efficiency of sandblasting, it is necessary to effectively separate the mixture of sand and dust recovered from the honeycomb floor. After the sand and dust are separated, the sand can continue to be recycled. The main function of the sand-dust separator is to efficiently and precisely separate the sand from the dust. The quality of the separation effect directly affects the sandblasting performance of the sandblasting machine and the filtration performance of the dust collector.
This sand and dust separator adopts a two-stage wind separator specially designed by our company for the sandblasting system. The first stage is a unique cyclone separator, and the second stage is a vibrating screen separator. It can effectively separate the sand and dust in the recovery system. The complete sand material after separation is returned to the main unit of the sandblasting machine for continued recycling, while the dust and crushed sand are sent to the dust collector. After filtration, it is stored in a dust storage cylinder for regular cleaning. The function of the cyclone inertial separator is to make the gas containing dust rotate and use the effect of centrifugal force to capture fine dust particles from the gas flow. This type of wind selection separator has a simple structure, stable performance, no moving parts, and is very convenient for maintenance and management. It is a widely used primary dust removal equipment, with a dust removal efficiency generally around 99%. The separator configured in this equipment adopts the latest structure and is precisely designed. At the lower end of the separation unit, there is a sand collector (storage box), and on the outside of the unit, there is a frame for maintenance and protection. The spiral body group on the separation unit is connected to the filter (filter element) dust collector, which is conducive to reducing noise and improving the quality of the working environment. By adjusting the regulating mechanism on the sand and dust separator, the diameter of the separated sand material can be adjusted. It is suitable for sand and dust separation occasions such as brown steel jade, steel shot, and steel sand, and has very strong applicability.
During the operation of the sand and dust separator, the parts that are subject to the high-speed impact of sand materials are vulnerable components. Our company has fully considered this issue in the design stage and has carried out reliable protection treatment on the interior of the pipeline, using highly wear-resistant materials to make protective plates. During the usage process, the protection plate can be inspected regularly. When the protection plate is worn through, it should be replaced in time to avoid wearing through the cylinder wall of the sand and dust separator and then repairing it. This way, the original appearance of the equipment can be guaranteed not to be damaged, and a lot of maintenance and repair time can be saved.
Storage hopper system
The storage hopper is one of the important components of the room equipment. All the sand materials, after being separated by the sand and dust separator, need to be stored briefly in the storage hopper. When the sand material in the sandblasting machine is used up, the storage hopper automatically replenishes the sand material into the sandblasting machine through the button on the panel of the electrical control box.
Sand return dust removal system
The dust removal system consists of suction and exhaust pipes, cartridge dust collectors, exhaust fans, exhaust chimneys and other components.
The working principle of the dust removal system:
In the sandblasting chamber, this dust removal system adopts a circulating dust collection treatment method with top air intake and bottom air exhaust. Clean air enters the sandblasting room from the top of the room. The dust removal fan sucks the polluted and turbid gas and sand materials in the room into the dust collector through each sand return port for collection and treatment. As the dust recovery suction inlet and the sand return inlet of the environmentally friendly pneumatic recovery type sandblasting room are all arranged under the honeycomb sandblasting floor, the air flow drives the dust to move from top to bottom all the time. The dust is always suppressed at the bottom of the sandblasting room. Therefore, the dust concentration in the space above 0.5 meters in the sandblasting room is very low, the visibility is very high, and the working environment is good.
Modular cartridge dust collector
The cartridge dust collector is a key component in the dust removal process of the sandblasting room. Its working condition directly affects the indoor environment and outdoor emission standards.
This dust collector is installed vertically, which has the advantages of high efficiency and easy dust cleaning compared with the common horizontal installation on the market. This dust collector's dust collection hopper is equipped with a dust collection cylinder and adopts a quick connection structure. It is sealed and easy to open. Cleaners can easily open it and pull it to the designated position to handle the dust. There is no need for other containers for transportation, which would cause secondary flying and pollute the environment.
The emission of this dust collector meets the national environmental protection standards, that is, ≤100mg/m ³, the captured particle size is > 5um, the resistance is < 400Pa, it has good air permeability, low resistance, low energy consumption and reliable filtration performance. The overall design structure of the dust collector is aesthetically pleasing, refined and stable (with an external steel structure frame and a single-side sealed and reliable inspection door). The filter cartridge assembly adopts a high-speed connection method. Meanwhile, the disassembly and assembly of the filter cartridges are very convenient, reducing the physical labor intensity of workers and improving working conditions.
The cleaning method of the dust collector is the key technology for whether the dust collector can be used normally. This dust collector adopts the pulse reverse blowing cleaning method. The working principle is as follows: When the pulse control instrument sends a signal, the exhaust port of the pulse control valve is opened, the gas pressure outside the back pressure chamber of the pulse valve is released, and a pressure difference is generated on both sides of the diaphragm. Due to the effect of the pressure difference, the diaphragm moves, and the pulse valve opens. At this time, compressed air is ejected from the air tank through the pulse valve and the small hole of the blow pipe (the gas ejected from the blow pipe is primary air). When high-speed airflow passes through the Venturi tube inducer, it induces several times the surrounding air (referred to as secondary air) of the primary air into the filter cartridge, creating an instantaneous positive pressure inside the filter cartridge and achieving the purpose of ash cleaning. The frequency and number of times of automatic pulse backblowing, including the backblowing time and sequence, are all controlled by PLC and can be flexibly adjusted according to actual usage requirements.
With the increasing attention paid by the state and various regions to environmental protection issues, the environmental protection level of equipment has become particularly important. During the design process of this set of equipment, the issue of this link was given special consideration to the customer. Adopt the most practical and reliable methods to meet the environmental protection requirements at all levels of the country and the local area where the equipment is used:
Treatment methods for granular dust:
This equipment achieves a dust removal efficiency of 99% by adopting a high-precision filter cartridge dust removal method. The dust filtration accuracy reaches 5um-10um, ensuring that the dust emissions meet national and local standards.
