在壓濾機設(shè)備中，filter plate是決定過濾效果和設(shè)備穩(wěn)定性的核心部件之一。濾板質(zhì)量的高低，直接影響過濾效率、濾餅含水率以及設(shè)備的使用壽命。蘇東壓濾機濾板作為壓濾機關(guān)鍵配套產(chǎn)品，憑借合理的結(jié)構(gòu)設(shè)計、穩(wěn)定的性能表現(xiàn)和良好的適應(yīng)性，被廣泛應(yīng)用于多個行業(yè)的固液分離工況中。

一、蘇東壓濾機濾板的結(jié)構(gòu)特點

蘇東壓濾機濾板在設(shè)計上充分考慮了過濾效率與密封性能的平衡。濾板表面溝槽分布均勻，有利于濾液快速排出，減少過濾阻力，提高整體過濾速度。邊框密封面平整度高，在壓緊狀態(tài)下能夠有效防止跑料、漏料現(xiàn)象的發(fā)生。

濾板整體結(jié)構(gòu)強度高，受壓均勻，在長期高壓過濾環(huán)境下不易變形，為壓濾機穩(wěn)定運行提供可靠保障。

二、濾板材質(zhì)與性能優(yōu)勢

蘇東壓濾機濾板通常采用高強度聚丙烯等材料制成，具有良好的耐壓性、耐腐蝕性和耐磨性，適用于多種復(fù)雜工況。針對化工、環(huán)保等對耐腐蝕要求較高的行業(yè)，濾板在材料配比和成型工藝上進行了優(yōu)化，能夠有效延長使用壽命。

同時，濾板表面光滑，濾餅易于脫落，有助于提高卸料效率，減少人工清理時間。

三、濾板規(guī)格齊全，支持定制

為滿足不同行業(yè)和不同處理量的需求，蘇東壓濾機濾板規(guī)格齊全，可匹配多種型號壓濾機使用。過濾面積、板框尺寸、進料方式均可根據(jù)客戶實際工況進行合理配置。

對于特殊物料或特殊工藝要求，蘇東壓濾機濾板還可提供定制化方案，在濾板厚度、進料孔位置及密封結(jié)構(gòu)等方面進行針對性設(shè)計，更好地滿足現(xiàn)場使用需求。

四、廣泛的應(yīng)用領(lǐng)域

蘇東壓濾機濾板已廣泛應(yīng)用于污水處理、污泥脫水、化工過濾、礦山選礦、食品加工等多個領(lǐng)域。在環(huán)保行業(yè)中，濾板能夠有效降低污泥含水率；在化工行業(yè)中，可滿足對耐腐蝕和密封性能的高要求；在礦山行業(yè)中，濾板結(jié)構(gòu)堅固，適合高壓、大處理量工況。

五、質(zhì)量控制與使用保障

蘇東壓濾機濾板在生產(chǎn)過程中實行嚴(yán)格的質(zhì)量控制，從原材料選擇、模壓成型到成品檢測，每一道工序均經(jīng)過嚴(yán)格把關(guān)。出廠前對濾板進行耐壓、密封和外觀檢測，確保產(chǎn)品性能穩(wěn)定可靠。

同時，廠家可為客戶提供濾板選型建議和使用指導(dǎo)，幫助客戶延長濾板使用周期，降低維護成本。

六、持續(xù)優(yōu)化與技術(shù)提升

隨著壓濾技術(shù)的發(fā)展，蘇東壓濾機濾板在結(jié)構(gòu)設(shè)計和材料工藝方面不斷優(yōu)化升級，在保證強度的同時，進一步提升過濾效率和耐用性，為企業(yè)生產(chǎn)提供更高效的支持。

concluding remarks

總體來看，蘇東壓濾機濾板憑借穩(wěn)定的質(zhì)量、合理的結(jié)構(gòu)設(shè)計和良好的應(yīng)用表現(xiàn)，已成為壓濾機配件中的重要選擇。無論是新設(shè)備配套，還是舊設(shè)備更換濾板，蘇東壓濾機濾板都能為用戶提供可靠的過濾保障。

• 濾布破損：濾布破損會導(dǎo)致壓濾機噴漿，需要定期檢查濾布是否存在磨損、破損等問題，并及時更換。同時，使用過程中需要避免使用硬物磕碰濾布表面，以免再次破損。為了解決這個問題，需要在使用過程中適時檢查壓緊機構(gòu)是否正常，調(diào)整壓緊力度和分配方式，確保濾布均勻受力。
• 壓緊機構(gòu)不當(dāng)：有時，壓緊力度不夠或分布不均等原因，也會導(dǎo)致壓濾機噴漿。為了避免這種情況，需要在使用過程中適時檢查壓緊機構(gòu)是否正常，調(diào)整壓緊力度和分配方式，確保濾布均勻受力。
• 除了以上原因，壓濾機還可能存在其他故障，如電源故障、傳感器故障等。如果以上方法無法解決問題，建議聯(lián)系專業(yè)的維修人員進行檢修處理。

1 Problems of moisture control in refined coal products

The refined coal of the plant consists of four sub-products, namely, heavy medium refined coal, final refined coal, primary flotation refined coal and secondary flotation refined coal, with the ratio of 0.55∶0.25∶0.12∶0.08. The four sub-products are produced by different equipments, and then uniformly enter into the refined coal belt, which is transferred to the refined coal silo to become the final refined coal product. The moisture fluctuation of any one of the sub-products will affect the moisture of the final refined coal product. In the case of fixed production process and equipment, the moisture of each sub-product depends on the process performance of the equipment. However, when the moisture fluctuates slightly within a production shift during the production process, the equipment is generally not overhauled, adjusted or replaced for the sake of continuous production. In the production process, every hour to do the ash check, but the moisture is not a candidate for "shipping moisture" as a guide, back to check the coal quality and equipment, moisture control lags behind. There are a lot of debris in the raw coal, cotton yarn, small pieces of wood and other items clogging the fine coal desorption sieve, centrifuge screen basket, affecting the effect of product dewatering; fine coal slime content in the raw coal is large, the coarse and fine coal centrifuge screen basket sticky slime, the effect of dewatering is poor. There is the phenomenon that the equipment is running and leaking, and there is the phenomenon that foreign water enters into the fine coal products, and at the same time, there is the phenomenon that the workers' sense of responsibility is not strong, and the belt machine and scraper machine bring the water directly into the fine coal products.

2 Main dewatering equipment and parameters for refined coal products

Fine coal product processing equipment of the Coal Processing Plant Headquarters includes 4 kinds of coarse fine coal centrifuge dewatering machines, fine coal mud centrifuge dewatering machines, fine coal mud sedimentation centrifuge dewatering machines and fine coal filter presses, and the dewatering requirements and process parameters of each dewatering equipment are different from each other, and the specific equipment models and technical parameters.

3 Specific measures to reduce the moisture of refined coal products

3.1 Enhanced cleaning of equipment

The coal preparation workshop refines the internal market implementation programme, formulates detailed equipment cleaning standards, rewards and penalties to the team, to the individual, and clarifies the acceptance signature process to ensure the effect of equipment cleaning. Enhance the cleaning of de-balling screen grading section during the stopping period to reduce the clogging of screen plate and ensure the normal grading of heavy fine; check the centrifuge screen basket and feel the centrifuge centrifugal liquid to ensure that the screen basket is intact; flush and clean the fine coal settling centrifuge screen basket and filter press cloth to ensure that the centrifuge screen basket, filter press cloth and filtrate nozzle are intact. During the production process, clean the debris on the screen grate every 1 h to ensure that the screen surface is free of debris and the screen holes are not blocked. Every 2 h on the coarse and fine coal centrifuge, arc sieve striker operation (striking interval time adjustment) and arc sieve dewatering effect of the inspection, and make relevant records, and found that the problem is timely reported to deal with. Observe the working condition of the arc sieve in the middle of the shift, and when there are phenomena such as water running away and material piling up on the surface of the sieve, according to the actual situation, take measures such as turning around, cleaning the surface of the sieve and replacing the surface of the sieve, so as to ensure the working effect of the arc sieve.

3.2 Enhanced maintenance of equipment

The installation and maintenance centre pays attention to the working condition of each dewatering equipment every day, analyses and finds out the reasons from the aspect of equipment when abnormal moisture occurs, and improves the performance of equipment by adjusting, replacing the accessories or transforming the equipment, so as to reach or exceed the dewatering performance of the equipment at the time of leaving the factory, and ensure that the moisture of the product meets the standard.The LLL-type centrifuges are measured once a shift, and the screen slits of the screen basket of the roughness and fineness centrifuges are maintained in the range of 0.35 to 0.4 mm. Replace the sieve basket when the sieve gap exceeds 0.4 mm after wear and tear. The screen basket gap is maintained at 1-3 mm, and once the gap changes, it will be adjusted in time by various methods to ensure the equipment process.

The parameters meet the requirements for coal selection.

The feeding pressure of the sedimentation centrifuge is around 0.3 MPa, if the pressure fluctuates, the feeding equipment will be overhauled immediately, the overflow parts will be replaced, and when the opening rate of the sieve slit decreases, it will be cleaned in coordination with the coal selecting workshop, so as to ensure the performance of the equipment. Filter press head feed pressure is between 0.7 and 0.8 MPa, feed pressure is between 0.5 MPa, and press pressure is around 0.6 MPa. The installation and maintenance centre always pays attention to the moisture of refined coal and the operation of the equipment, and if the pressure fails to meet the requirements, it will find out the reasons for the equipment at the first time, and if it is necessary to change the pump, it will be changed under the arrangement of production scheduling, so as to reduce the moisture of refined coal. Make two-dimensional code for each dewatering equipment and install it in the appropriate position of the equipment. When the chartered personnel of the installation and maintenance centre inspect the equipment, they can scan the code to fill in the basic information of the equipment and the inspection and maintenance records, which will form the equipment history file and the maintenance record file. According to the equipment files, a dynamic maintenance schedule can be formed to remind the team of the maintenance deadline in real time, helping the team to arrange preventive maintenance measures in advance, and improving the planning and reliability of equipment maintenance.

3.3 Strengthening production process control

There are many factors affecting the product moisture, Huaibei Coal Preparation Plant adopts QC total quality management, systematically analyses the factors affecting the moisture of each sub-product of refined coal, takes targeted measures, strengthens the control of the production process, and reduces the influence of the influencing factors on the sub-products of refined coal. Coal processing workshop coal every 10 min record of raw coal into the wash, to ensure that the supply of raw coal as far as possible uniform and stable, the processing speed control in the range of 310 ~ 330 t / h; reasonable adjustment of the vibrating screen de-mediation of circulating water dosage, to maintain a stable level of coarse coal slurry barrels, fine coal slurry drums, to ensure that the head of the arc screen material supply is stable; to maintain flotation into the quality of the concentration of material in the 80 ~ 90 g / L, to ensure that the quality concentration of flotation material stable [2]. Maintain the quality concentration of flotation feed at 80~90 g/L, ensure the flotation feed quality concentration is stable [2]; keep the liquid level of the material in the second flotation drum not less than 200 cm, ensure the feed of the second flotation filter press is sufficient; strictly control the use of anti-foaming water in the concentrate tank of the flotation machine, reduce the viscosity of the flotation foam, and improve the processing effect of the fine coal filter press. Strengthen the raw coal removal in the coal processing workshop to reduce the debris in the system and prevent the debris from clogging the sieve plate and screen mesh; increase the heavy-medium diversion to reduce the amount of coal sludge in the system and reduce the output of flotation coal; check whether the belt machine and scraper are stocked with water before starting the operation; and strictly manage the operation of centrifugal machines and filter presses to prevent the centrifugal liquid, filter press filtrate and other external water from entering the refined coal products. The quality inspection workshop carries out the moisture inspection of the primary flotation and secondary flotation of heavy-medium lump fine coal and coarse fine coal within 1 hour after adding coal in each shift. During the production process, when the moisture of heavy-medium lump coal is more than 5% and the moisture of rough coal is more than 13%, the chemist will report to the dispatching in time, and the dispatching will notify the coal selecting workshop and the safety and maintenance centre to investigate and deal with the problems on the spot, and reduce the moisture as soon as possible; when the moisture of heavy-medium lump coal is more than 6% and the moisture of rough coal is more than 15%, the dispatching will arrange to stop the car to deal with the problem, and only when the problem is solved can it start to add coal to production. Only after the problem is solved can the company start to add coal for production. During the production process, the final product moisture is weighted according to the output and moisture of each sub-product to guide the production control, changing the previous practice of passively controlling the moisture of fine coal products by "shipping water". The company has established a big data analysis library of coal production, including the production date of heavy media parameters, washing programme, raw coal information, production process and abnormalities, and analysed and recorded the production situation of the current shift after each shift, so as to provide references for the future production. At the same time, we firmly implement the "large diversion and water replenishment operation method, and systematically carry out mud removal to reduce the impact of high ash and fine mud on the dewatering process of fine coal products [3].

3.4 Enhancing technological transformation

After thorough investigation and demonstration, the coal preparation plant has implemented targeted technical modifications to further improve the reliability of the equipment and strengthen the foundation of reducing the moisture content of the refined coal products. Replace the coarse and fine coal arc sieve with a high aperture rate sieve plate with a slit of 0.4 mm and a back width of 0.8 mm, increase the coarse cut-off volume of the arc sieve, reduce the flotation feed volume of 20%, and improve the proportion of fine coal sub-products. Increase the arc screen exciter and striker to improve the working effect of the arc screen and reduce the moisture of the centrifuge feed. Compare withFilter Press ManufacturersIn cooperation with the company, we installed edge-feeding type filter press for secondary flotation concentrate dewatering, after the transformation, the press pressure of the filter press was increased from 13 MPa to 20 MPa, and the filtration area was increased from 490 m2 to 550 m2, so as to solve the problem of high moisture of the cake of KZG-type concentrate filter press while increasing the processing capacity. Open holes in the outer wall of the centrifuge, and draw high-pressure wind from the high-pressure air package all the way to the inside of the centrifuge, forming five air outlets facing the screen; install an electromagnetic blowing valve on the air package pipeline, and realise the function of blowing automatically for 30 s immediately after stopping the car through a relay and a time-delay controller, so as to blow off the debris adhering to the screen, and improve the working performance of the centrifuge. The research and development of the "unattended" system in the coal receiving pit realises that the coal feeder automatically allocates and adds coal according to the storage condition in the coal receiving pit, so as to supply coal of uniform quality and quantity to the maximum extent possible, and to reduce the influence of the change of coal quality and quantity on the production system.

3.5 Enhanced experimental analyses

Product quality inspection is the "eyes" of coal preparation plant, and experimental analysis is necessary to promote the "health" of coal preparation production system, which can provide the basis for guiding the production and optimising the production plan. Coal processing workshop, together with quality inspection workshop, carries out experimental comparative analysis of process adjustment, such as whether the materials in three or four rooms of primary flotation enter the secondary flotation machine, whether the materials in one or two rooms of primary flotation are doped with coarse or not, whether the heavy media slurry bucket is replenished with water or not during the large diversion, etc, in order to search for the best control scheme of moisture of refined coal products. The quality inspection workshop carries out "key moisture point" test, strengthens the statistical analysis, weekly, monthly, every ten days statistics of heavy medium, coarse and fine, primary and secondary flotation moisture changes, and guides the operation of dewatering operation of the coal processing workshop with the phased rule. According to the raw coal quality and incoming material quality concentration, particle size, viscosity, optimise the operating parameters of sedimentation centrifuge and filter press to ensure that the product moisture meets the standard. Carry out "comparative" test for dewatering equipment. Follow up the single and double dewatering equipments, compare the moisture, and provide timely feedback. We benchmark the advanced value of similar equipments in the industry, carry out targeted benchmarking management and promotion work, continuously track the dewatering situation after adjusting and maintaining the dewatering equipments, and then optimise and adjust the equipments again, so as to make the equipments reach the best working efficiency. Carry out experiments on parameters such as press pressure and press time of the filter press, and finally conclude that under the conditions of feed pressure of 0.6 MPa, feed time of 420 s, press pressure of 1.0 MPa, press time of 300 s, and side blowing pressure of 0.7 MPa, extending the side blowing time to 900 s can achieve better moisture index of secondary flotation coal products. Carry out experiments on the effect of overflow weir height of sedimentation centrifuge on products, and finally conclude that with the increase of overflow weir height, the diameter of gas-liquid interface decreases, the length of settling zone increases, the separation strength decreases, the average particle size of solid products decreases, the moisture of products increases, and the solids content in filtrate decreases. Reasonable selection of the optimal overflow weir height can reduce the moisture of the primary flotation coal product to a certain extent.

3.6 Strengthening education and training

The coal industry has been transformed from the past kind of rough and labour-intensive to knowledge-based technology, and in order to survive in the wave of reform, the enterprise must educate and train the workers, enhance their sense of belonging to the enterprise and sense of ownership, and consciously think about what the enterprise thinks and urgently need the enterprise's urgency. Carry out staff education and training, explain the importance of moisture index of fine coal, form a good atmosphere that everyone pays attention to the moisture index and participates in the control of the moisture index, and promote the maximisation of the enterprise's benefit. Systematically collate the factors affecting refined coal products, decompose them in a targeted way, and form operation points, so that the workers understand what to do, how to do it, and to what extent to do it; organise the relevant units to carry out the "Reducing the moisture of refined coal products" discussion activities by workshop, team and post, so as to collect ideas and promote the reduction of the moisture of refined coal products. According to on-site practice, carry out the abnormal treatment method of fine coal product moisture.

Summarise, combined with the post operation points, post common problems, post standardized operating procedures, etc. to do a good job in reducing the water content of fine coal products micro-course development, evaluation, hanging on the Internet, convenient for workers to consult and learn; organise knowledge and experience dissemination meetings, increase the strength of the post to pass on the efforts of the technical inheritance, and promote the skills of workers as a whole team to improve. Organize the revision of post operation process, promote work standardization, normalization, institutionalization, scientification; vigorously carry out technical competitions, "master and apprentice" activities, to create a "compare, learn, catch up, help and surpass" a good learning and competitive environment, to create a theoretical, technical and high-quality talent team. High-quality talent team.

3.7 Increased appraisal

Appraisal is the baton of behaviour, Huaibei Coal Preparation Plant clarifies the moisture control index of fine coal products and the moisture control index of fine coal sub-products, and increases the appraisal, so as to make the system become a strong backing to promote the reduction of the moisture of fine coal products. The leading group of the project to reduce the moisture of refined coal was set up to determine the moisture control target according to the current status of the process and the performance of the equipment: the moisture of the shipped refined coal is less than or equal to 9.5%, the moisture of the heavy-medium refined coal is less than or equal to 3.5%, the moisture of the coarse refined coal is less than or equal to 10.0%, the moisture of the primary flotation refined coal is less than or equal to 20.0%, and the moisture of the secondary flotation refined coal is less than or equal to 15.0%. Implementing the "double equal" assessment system, i.e., equal assessment of refined coal moisture and ash content, equal assessment of coal processing workshop, quality inspection workshop and installation and maintenance centre, to promote the coal processing workshop, quality inspection workshop and installation and maintenance centre to strengthen the communication and liaison, and to analyse and find out the reasons from the aspects of coal quality, equipment and operation, so as to make the moisture of refined coal products reach the assessment level and to ensure the quality of coal products meet the requirements. To make the moisture of fine coal products meet the assessment requirements. Scheduling coordinator does a good job in coordinating the work, and makes it clear that all relevant departments will sort out the details of materials needed to reduce the moisture content of refined coal products before the 20th of each month and report the material plan, and the material management department will contact the material branch of the group company to make purchases in a timely manner, track the arrival situation and issue the materials in a timely manner. The quality analysis meeting is held every month, in which the chief engineer of the plant, the relevant functional departments and the main leaders of the coal selecting workshop, quality inspection workshop, installation and maintenance centre and other workshops participate to analyse the coal quality situation, systematically find out the existing problems and improve them, and carry out rewards and punishments according to the completion situation, so as to promote the moisture control to meet the target requirements.

4 Conclusion

Product quality is the cornerstone of enterprise development. As an important indicator of product quality, especially for coking coal products, the moisture of fine coal will affect the coke yield and comprehensive energy consumption of downstream coking enterprises, increase the amount of ineffective transportation, increase the cost of transportation, and pollute the environment around the transportation line. This is contrary to the national carbon peak carbon neutral target and must be taken seriously. Through a series of measures, the headquarter of Huaibei Coal Preparation Plant has reduced the moisture of refined coal products from 10.2% to less than 9.5%, which is a very significant result and provides a useful reference for the control of moisture of refined coal products in the industry.

Sudong or Sodong (name)filter press 18851718517

1Working Principle of Quick Opening Filter Press

1.1 The composition of the fast-opening filter press fast-opening filter press by the frame, the main beam, filter plate, thrust plate, spacer plate, compression plate, seat, cylinder body, unloading mechanism, hydraulic station, electrical control components.

1.2 Working principle of quick-opening filter press The filter plate of quick-opening filter press consists of diaphragm plate and compartment plate, the piston rod on the cylinder body pushes the compression plate, and the diaphragm plate and compartment plate and filter cloth located between the compression plate and thrust plate are pressed to ensure that there is a pressure of slurry in the filter chamber for pressurised filtration, due to the diaphragm plate, the compressed air can be passed through the air intake port of the diaphragm plate to squeeze the filter cake and further reduce the water content of the filter cake. Due to the diaphragm plate, compressed air can be fed into the air inlet of the diaphragm plate to press the filter cake to further reduce the water content of the filter cake, and high-pressure air can also be fed into the inlet at the end of the thrust plate to carry out the intermediate air penetration through the layer of the filtering cloth to blow out the intermediate mud. There is also a part of the host to complete the power device of the pressure and release, under the action of the electronic control cabinet system, through the oil cylinder, oil pump, and hydraulic components to complete part of the system, when the system is pressed to seal the various chambers for filtration, and vice versa, loosened for unloading. The unloading part mainly consists of two gear motors and transmission shafts, sprockets, chains and other main parts, working under the action of electrical system. When the compression plate is loosened, the stop push a 1-move, the motor at the position of the support seat starts, pulling the cylinder seat and the compression plate through the chain to pull open the first part of the filter plate, the motor at the position of the stop push plate starts to drive the spacer to pull open the second part of the filter plate through the signal transmission in the electric control cabinet to make it reverse, driving the spacer to pull open the remaining filter plate so that the discharging process is completed. The machine has two working modes, automatic and manual, in automatic mode, the whole action process of the filter press will run in sequence according to the design procedure without manual intervention, and its running process is as follows: firstly, close the air switch, set the selector switch in the automatic position, press the procedure button, the pump station motor starts to start, and at the same time, release the electromagnetism valve is charged, and the pressing plate backs up, and touches the limit proximity switch to press the plate and stops automatically. Backward, at the same time stop push electromagnetic broad charged, stop push push move, contact with upward limit switch upward stop, at the same time the pump station motor stops running, pull the plate motor (stop push plate position) to start, drive the cylinder seat to move (once pull the plate unloading) to the limit switch motor stops, at the same time the pull the plate motor (stop push the plate position) start to drive the spacer plate to move (second pull the plate unloading) to the limit of the proximity switch, the motor reversed, drive the The partition plate moves in the opposite direction (three times pull the plate unloading) to the limit close to the switch motor stops, while pulling the plate motor (stop pushing the plate position) to start driving the cylinder seat to move (close the plate) to the limit close to the switch after the motor stops, at the same time, the pump motor to start the pumping solenoid valve is charged to stop the push push to move down, after contacting the limit switch stop pushing the solenoid valve is deenergised, at the same time, the pressure solenoid valve is charged to carry out the compression action to reach the upper limit of the pressure to the upper limit of the switch to the After reaching the upper pressure limit, it will turn into the pressure-keeping state, and the pump station motor will stop and start feeding, so that a working cycle will be completed. In manual mode, each action of the filter press is completed by manually operating each button, this mode is mainly used for debugging equipment, in addition, in the process of unloading, manual assistance is required or other circumstances, the unloading can be interrupted through the pause device, after the manual clearing is completed, the pulling of the plate to continue.

2 Failure analysis through the use of the filter press more than a year of the problems that occur, the analysis of the failure of three categories:

①Electrical faults: the main limit close to open the fault, solenoid valve failure, relay failure, electric contact pressure gauge failure and so on.

② mechanical failures: broken filter plate filter cloth, valve damage, damage to the climbing chain, pull the plate mechanism and other failures.

③ Hydraulic system failure: mainly hydraulic valve damage or clogging.

3 Troubleshooting methods

3.1 Electrical faults

1) in the operation of the programme to a certain procedure does not act, for example: stop push push down overtime compression is not carried out, first of all, to check the stop push down to move in place close to the switch whether there is a problem, such as the problem of replacing the close to the switch that is meh, if the up to move in place close to the switch is not extinguished, but also lead to the down to move overtime replacement of the close to the switch can be.

2) Pump station solenoid valve failure, resulting in not pressing or not loosening. Repeatedly stop the push pin does not move up or down, the treatment is to check whether the corresponding solenoid valve is electric or solenoid valve coil burned out, replacement can be.

3) electric contact pressure gauge failure, compression overtime or venting overtime is the electric contact contacts have problems, the treatment method is to adjust or replace.

4) the valve solenoid valve failure, such as a wind control valve should be opened when not open or closed when not closed, to check whether the valve solenoid valve coil is electrically charged, or whether the coil is burned out, the treatment method for the inspection of the line and relay or replacement of the coil, if it is the opening of the valve is open, it should not be open also open, it is possible that the solenoid valve line is connected to the electricity or the junction box into the water.

3.2 Machine-type failures

1) Leakage between the filter plate and the diaphragm filter plate, the reason is that there are sundries between the filter plate, the filter cloth is not flat and folded or the filter cloth is broken. Treatment: clean up the debris, organise and replace the filter cloth.

2) Filter plate rupture, the reason is that the broken filter cloth causes sandwich, the cake is not full of filter chamber before pressing, the filter plate inlet and outlet are blocked. Treatment: Replace the filter cloth in time, press the cake after filling the filter chamber, and clean the inlet and outlet ports.

3) The bearing of pulling plate shaft is damaged or broken, which will lead to the noise when pulling plate or pulling plate slanting, and should stop unloading in time. Treatment: replace the shaft and bearings, pulling the plate small chain broken will also lead to the filter plate tilt, should also stop discharging in time to replace the small chain.

4) Insufficient holding pressure due to worn piston seals and oil leakage in the oil circuit. Treatment: replace the seal to check the oil circuit.

5) The filtrate is not clear, the reason is that the filter cloth is worn, the filter cloth is not properly selected, the filter cloth stitching is open. Treatment: Replace the filter cloth.

3.3 Failure of the hydraulic system

1) insufficient holding pressure, the reason is that the liquid-controlled check valve out of control, treatment: replace the cleaning liquid-controlled check valve.

2) insufficient oil pressure, the reason is the relief valve is bad, oil level is insufficient, oil pump wear, bad valve or joint leakage, cylinder seal wear valve leakage, treatment: repair or replace the relief valve, refuelling, replacement of the oil pump, tighten the joints, replacement of the O ring or replacement of the seal.

3) hydraulic system noise, the reason is that the cylinder sucks in air, loose fasteners, hydraulic oil viscosity, treatment: open the bleeder valve bleed, will be loose fasteners fastened, replace the hydraulic oil.

4 Conclusion through the fast-opening pressure filter running more than a year to do an in-depth understanding of the common failures of the analysis, put forward a reasonable method of treatment, in the daily use and maintenance as long as a good grasp of the principle of conscientious operation will be able to improve the stability of the filter press, so as to better safeguard the normal production of the coal washing plant.

Filter press technical support: 18851718517

Sudong or Sodong (name)Professional production of filter press manufacturers是國內(nèi)參與壓濾機行業(yè)標(biāo)準(zhǔn)制定廠家，“suton”牌壓濾機已廣泛應(yīng)用于市政污水、工業(yè)廢水、氯堿化工、冶金、印染、陶瓷、食品、醫(yī)藥、鋼鐵、礦山、石油煤炭、精細(xì)化工、環(huán)保等各行業(yè)廢液處理、原料生產(chǎn)過程中的固液分離及回收利用，在多個領(lǐng)域的固液分離中占有主導(dǎo)地位。我們的用戶覆蓋全國各省、市、自治區(qū)，并陸續(xù)出口俄羅斯、印尼、委內(nèi)瑞拉、土耳其、墨西哥、蘇丹、孟加拉、朝鮮等國家和東南亞地區(qū)，產(chǎn)品質(zhì)量已得到全球客戶的一數(shù)認(rèn)可和好評。

Founded in June 1956, suton filter is engaged in the research, design and manufacture of filter presses for more than 30 years, and is a domestic manufacturer involved in the formulation of industry standards for filter presses. The company covers an area of 100,000 square metres and has more than 500 employees, including 105 engineers and technicians of various types. The company has excellent equipments, complete testing means and strict quality management, and has established long-term and stable technical cooperation relationship with Fudan University, Shanghai Jiao Tong University, Jiangsu University, Changzhou University, Beijing Technology and Business University and other famous scientific research colleges and universities. We have "Solid-liquid Separation Engineering Technology Research Centre" built with Jiangsu University and awarded "Jiangsu Postgraduate Workstation". The company owns a number of national invention patents and intellectual property patents, and has become one of the well-known enterprises in the manufacturing industry of composite rubber plates, reinforced polypropylene plates and high-pressure diaphragm plate filter presses after more than thirty years of experience and technological innovation.

“蘇東”牌壓濾機被授予?“江蘇省高新技術(shù)產(chǎn)品”、“江蘇省用戶滿意產(chǎn)品”、“江蘇省質(zhì)量信得過產(chǎn)品、“江蘇名牌產(chǎn)品”、“中國市場知名品牌”和“中國壓濾機質(zhì)量公認(rèn)十大知名品牌”稱號。公司已通過ISO質(zhì)量管理體系認(rèn)證達(dá)十多年，獲得多項市科技進步獎，被授予江蘇省高新技術(shù)企業(yè)，被評為江蘇省環(huán)保百強企業(yè)。

Disclaimer: The copyright of this article belongs to the original author and the original source. Welcome to call us for consultation, technical exchanges, and material experiments.

Enquiry: 188517-18517

用于各種懸浮物料固液分離提高分離效 率、降低濾餅含水率的理想設(shè)備。廣泛應(yīng)用于石油、化工、印染、冶金、醫(yī)藥、食品、紡織、電 鍍、造紙及城市生活污水處理等行業(yè)的各種固液分離領(lǐng)域。

壓濾機采用機、電、儀一體化設(shè)計制造，能根據(jù)用 戶的需求， 實現(xiàn)濾板液壓壓緊、自動保壓、過濾、壓榨、吹氣、洗滌、濾板松開、卸料等工序的 自動化控制。該機型配置了隔膜板， 進料過濾后， 通過水壓或氣壓的方式改變?yōu)V室容積，對濾餅進行壓榨， 進一步降低含水率。過濾板和隔膜壓榨板采用優(yōu)質(zhì)增強聚丙烯復(fù)合材料模壓成型，具有機械強度高、化學(xué)性能穩(wěn)定， 耐酸、耐堿、抗老化、無毒、無味、堅固耐用； 電器元件和液壓 元件均采用名牌廠家產(chǎn)品，使用壽命長；機架采用優(yōu)質(zhì)鋼板焊接而成，強度高、經(jīng)久耐用。

This series of filter presses implement the standard: JB/T4333-2005 "chamber filter press technical conditions".

主要參數(shù)：

The final explanation of this product belongs to su-ton and is subject to change without prior notice.

下單請聯(lián)系我們銷售人員，謝謝！

500平方板框壓濾機技術(shù)參數(shù)及更多壓濾機參考數(shù)據(jù)可查閱以下表格：

Disclaimer: The copyright of this article belongs to the original author and the original source. Welcome to call us for consultation, technical exchanges, and material experiments.

Enquiry: 188517-18517

Coal Preparation Plant Filter Press設(shè)備選型。重介選煤工藝在我國煤炭洗選加工領(lǐng)域已得到了廣泛應(yīng)用,尤其在晉蒙陜等煤炭主產(chǎn)區(qū)。經(jīng)過幾十年的生產(chǎn)實踐和科學(xué)研究,我國煤炭工業(yè)得到了進一步發(fā)展,重介選煤技術(shù)日趨成熟,重介選煤裝備也有了長足的進步。根據(jù)入洗原煤煤質(zhì)、工藝特性,如何科學(xué)、合理地選用選煤設(shè)備已成為各科研院所、選煤廠共同探討的問題。中天合創(chuàng)能源有限責(zé)任公司下設(shè)葫蘆素、門克慶2座千萬噸礦井,井田均位于東勝煤田呼吉爾特礦區(qū),地處內(nèi)蒙古自治區(qū)鄂爾多斯市境內(nèi),行政區(qū)劃隸屬烏審旗圖克鎮(zhèn)管轄。葫蘆素、門克慶2座選煤廠是中天合創(chuàng)鄂爾多斯煤炭深加工示范項目重要配套建設(shè)工程,負(fù)責(zé)供給煤化工項目生產(chǎn)用煤。2座礦井配套的選煤廠均為礦井型大型動力煤選煤廠,分別由中煤集團下屬的西安、天津2家設(shè)計院同時開展設(shè)計,并同步建設(shè)、調(diào)試和投產(chǎn)。葫蘆素選煤廠設(shè)計能力13.00Mt/a,服務(wù)年限為90.0a。選煤廠于2016年1月建成投用,入選煤種為不粘煤,選煤工藝采取150~13mm塊煤重介淺槽分選、小于13mm末原煤不入洗、煤泥加壓過濾機和快開壓濾機聯(lián)合回收。主要工藝系統(tǒng)包括:原煤儲存和準(zhǔn)備、原煤洗選加工、煤泥水處理及煤泥回收、產(chǎn)品儲存及裝運等。門克慶選煤廠建設(shè)規(guī)模12.0Mt/a,設(shè)計服務(wù)年限92.0a。選煤廠于2016年10月建成投用,入洗煤種為不粘煤、弱粘煤。選煤工藝與葫蘆素選煤廠相同。

2選煤廠設(shè)備選型總體思路及原則

2.1設(shè)備選型原則本著先進、成熟、經(jīng)濟的原則,在同等技術(shù)條件下,優(yōu)先選擇信譽好、質(zhì)量可靠、業(yè)績較多的設(shè)備生產(chǎn)廠商。根據(jù)生產(chǎn)工藝要求,重要生產(chǎn)環(huán)節(jié)的關(guān)鍵設(shè)備選用進口組裝設(shè)備,其余設(shè)備選用國內(nèi)經(jīng)生產(chǎn)實踐證明可靠、先進的設(shè)備。在保證設(shè)備性能的前提下,2座選煤廠盡可能實現(xiàn)設(shè)備的互用互備,同類設(shè)備盡量選擇同系列、同規(guī)格,減少不同規(guī)格的品種和數(shù)量,便于設(shè)備維護和備品備件的互換使用,減少后期生產(chǎn)運營成本,降低設(shè)備故障帶來的風(fēng)險。選煤廠規(guī)模的大型化必須依賴于選煤裝備的大型化。大型設(shè)備的采用給選煤廠帶來的優(yōu)勢是系統(tǒng)簡單、投資降低、操作人員少,這與企業(yè)規(guī)模經(jīng)營、降低成本的生產(chǎn)經(jīng)營理念相契合。關(guān)鍵工藝設(shè)備選型時,堅持選用大型、自動化程度高的設(shè)備,同時盡量減少設(shè)備臺數(shù)。在生產(chǎn)實踐中發(fā)現(xiàn),設(shè)備臺數(shù)越多,生產(chǎn)過程中故障點就越多,故障停車的可能性就越大,不利于生產(chǎn)的連續(xù)、穩(wěn)定、高效運行。

2.2不均衡系數(shù)的選取

(1)原煤儲存之前,設(shè)備處理能力與礦井提升能力相適應(yīng)。

(2)原煤儲存之后,在與礦井能力配套的前提下,根據(jù)《煤炭洗選工程設(shè)計規(guī)范》(GB50359—2016),當(dāng)采用塊、末煤分級入選工藝時,煤流系統(tǒng)和重介懸浮液系統(tǒng)不均衡系數(shù)取1.25,煤泥水系統(tǒng)不均衡系數(shù)取1.35,矸石系統(tǒng)不均衡系數(shù)取1.50。

3主要設(shè)備選型

3.1主要設(shè)備簡述

(1)大塊原煤分級篩。選用進口組裝的3.0×6.1單層圓振動篩,傾角20°,篩孔為150mm。該篩分機處理量大,篩分效率高,適合原煤分級,單臺通過量可達(dá)2900t/h,運行平穩(wěn)可靠,噪聲低,維修方便。

(2)大塊原煤破碎機。選用進口液壓可調(diào)雙齒輥破碎機,入料上限350mm,可有效應(yīng)對礦井原煤波動時引起的原煤粒度超標(biāo)。采用平行齒設(shè)計,非螺旋齒,避免了過硬的物料對螺旋齒產(chǎn)生軸向力。防止產(chǎn)生破碎軸軸向竄動,避免了由于軸向竄動而引起的軸承損壞。破碎輥直徑850mm,抗彎及抗剪強度高。破碎板采用獨特的固定方式,可以快速更換,有效地降低停機檢修時間,單臺處理量為400t/h,運行3a來未發(fā)生重大機械故障。

(3)原煤分級脫泥篩選用進口組裝的4.2×8.5單層多角度香蕉篩,入料段篩孔為13mm,出料端1800mm長篩板篩孔為3mm。該篩分機單臺通過量可達(dá)735t/h,處理量大,篩分效率高,可以簡化系統(tǒng),減少設(shè)備臺數(shù)。該設(shè)備分級脫泥效果好,運行平穩(wěn)可靠,噪聲低,維修方便。

(4)塊原煤破碎機。選用國產(chǎn)新型分級式破碎機。該機利用剪切力和拉力破碎物料,并具有篩分、破碎雙重作用,該設(shè)備單臺處理量為1572t/h,具有強度高、耐磨性強、高度低、體積小、重量輕、運轉(zhuǎn)平穩(wěn)、噪聲低、粉塵污染小、精確控制排料粒度、磨損量小、能耗低、可靠性高等優(yōu)點。

(5)脫介篩。塊精煤脫介篩選用進口組裝的3.6×7.3單層直線振動篩,其出料端設(shè)有長1200mm,篩縫為30(50)mm的分級篩板,具有分級作用。其余均為脫介段,脫介篩孔為1mm,單臺處理量為331t/h,脫泥、脫介效果好,運行平穩(wěn)可靠,噪聲低,維修方便。矸石脫介篩選用進口組裝的2.4×6.1單層直線篩,篩孔為1mm,單臺處理量為143t/h。

(6)重介淺槽分選機。20世紀(jì)90年代末,安太堡選煤廠首次從美國引進重介質(zhì)淺槽分選機,用于分選150~13mm粒級塊煤。由于淺槽在工藝上具有分選精度高、塊煤破碎率低、次生煤泥少、矸石帶煤量少的優(yōu)勢,同時具有易操作、易維護、低投資和高效率的特點,因此,在我國很快得到認(rèn)可。2座選煤廠均選用進口組裝的B=7.9m淺槽分選機,單臺處理量為760t/h,布置簡單,維護方便。并使用了特殊耐磨性的墊板,特殊設(shè)計的高鉻鋼加長耐磨傳動鏈以及安裝在軸上的減速器,從而使設(shè)備使用壽命與操作簡易程度大大提高。

(7)末精煤離心機。選用進口組裝的臥式振動離心脫水機。該機采用亞振動原理,實現(xiàn)篩籃軸向振動,保證產(chǎn)品水分不受入料量波動的影響。整機設(shè)備性能好,產(chǎn)品水分低,運行平穩(wěn)可靠。具有占地面積小,檢修方便,性價比高等優(yōu)點。

(8)磁選機。選用進口組裝的φ1219×2972濕式滾筒磁選機,逆流式。該設(shè)備磁選效率高,處理量大,磁體采用優(yōu)質(zhì)的磁性材料制成,退磁率低,滾筒采用135°超大磁角,增加磁選機捕捉磁性物的能力,磁選機磁精礦回收率高。

(9)濃縮機。濃縮機選用中心傳動的φ40m、帶扭矩監(jiān)測分段自動提耙裝置的高效濃縮機。該機型采用中心深層入料、平流沉降原理,處理能力大,方便檢修。整機采用PLC程序控制,實現(xiàn)超載報警指示,可自動、手動并遠(yuǎn)程集控。煤泥高效濃縮機的入料方式、加藥點、驅(qū)動均與傳統(tǒng)濃縮機不同,因而對固液的分離效率高。這種高效濃縮機配有入料緩沖、排氣裝置,煤泥水從入料井的中心下部低于液面約1m切線穩(wěn)定給入,從中心到周邊溢流槽固液分離的運動軌跡呈曲線型,物料從進入中心入料點到溢流槽所用的時間是同直徑傳統(tǒng)濃縮機的3.75倍,即當(dāng)量直徑是傳統(tǒng)濃縮機的3.75倍。濃縮機的旋轉(zhuǎn)和提耙分別由旋轉(zhuǎn)和提耙裝置完成,當(dāng)扭力超過設(shè)定值時,濃縮機耙架將被自動提起直到高扭力報警消除。

(10)煤泥脫水設(shè)備。在選煤廠煤泥脫水設(shè)備中,目前使用較多的有壓濾機、加壓過濾機等。2座選煤廠設(shè)計從簡化流程、提高系統(tǒng)穩(wěn)定性的角度出發(fā),細(xì)煤泥采用一段回收工藝,煤泥采用加壓過濾機和快開壓濾機聯(lián)合回收。既能充分發(fā)揮加壓過濾機處理能力大、脫水效果好、產(chǎn)品形狀好的特點,也能發(fā)揮快開壓濾機對細(xì)顆粒捕收能力強、濾液濃度低的特點,實現(xiàn)優(yōu)勢互補。2座選煤廠快開壓濾機選用國產(chǎn)600m2型高效隔膜壓濾機。該機具有工作循環(huán)短、單臺處理量大、濾餅水分低、單機自動化水平高、運行可靠等特點。加壓過濾機選用國產(chǎn)的GPJ-120型加壓過濾機。該機產(chǎn)品水分低、處理量大,具有高可靠性、智能化自動控制、適應(yīng)能力強等特點。在國內(nèi)煤炭、冶金工業(yè)都有應(yīng)用,有效地解決了產(chǎn)品水分和均勻摻混的難題。

(11)輸送設(shè)備。帶式輸送機作為選煤廠的主要輸送設(shè)備,必須具有性能可靠、運行穩(wěn)定、故障率低等特點。帶式輸送機除滿足目前輸送能力的要求外,還應(yīng)兼顧選煤廠長遠(yuǎn)發(fā)展的需要;考慮到帶式輸送機設(shè)置在廠房、棧橋內(nèi),為降低震動、噪聲和保證安全生產(chǎn),帶式輸送機帶速按不大于4.0m/s的原則進行設(shè)計。對輸送機傾角較大時可能出現(xiàn)的撒料、滾料等現(xiàn)象,采取適當(dāng)降低帶速、提高帶寬、增加裝滿系數(shù)予以解決。刮板輸送機與帶式輸送機相比,具有能耗高、故障率高、維護量大等缺點,但對于廠房內(nèi)的短距離運輸來說具有不跑偏、不撒料及可實現(xiàn)多點卸料等優(yōu)點。鑒于此,盡量避免采用刮板輸送機。在無法布置帶式輸送機的地方以及小運量的情況下采用了刮板輸送機。刮板輸送機驅(qū)動裝置具有傳動效率高、體積小、壽命長的特點;所有刮板輸送機的運行速度均小于1.0m/s;所有型號相同的減速器出軸布置方式應(yīng)盡量相同,以減少備品備件種類。功率大于37kW的刮板輸送機設(shè)置快裝型液力偶合器;所有刮板輸送機上槽箱全部密封,密封蓋板厚度6mm、并設(shè)有加強筋板;同時配有蝸輪渦桿和絲杠2種緊鏈裝置。

3.22座選煤廠主要工藝設(shè)備選型2座選煤廠主要工藝設(shè)備選型見表1。

4投產(chǎn)實踐效果

(1)2座選煤廠自2016年投產(chǎn)以來,由于在設(shè)備選型時合理考慮了富裕系數(shù),增大了生產(chǎn)組織的靈活性,極大程度上減少了設(shè)備的故障率,停車延誤時間較少,累計日停車延誤時間僅為0.5h,提高了設(shè)備的開機率,實現(xiàn)選煤廠高產(chǎn)高效生產(chǎn)。

(2)由于2座選煤廠同時設(shè)計、施工,設(shè)備選型及采購基本相同,運營過程中2座選煤廠可充分實現(xiàn)設(shè)備、大部件、材料的聯(lián)儲互備,極大地降低了企業(yè)生產(chǎn)成本,合理地降低了企業(yè)資金占用水平,同時落實了中天合創(chuàng)公司輕資產(chǎn)運營管理策略,在保障2座選煤廠生產(chǎn)正常運營的同時,減少資金占用,進一步向物資管理要效益,經(jīng)濟效益顯著。

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煤礦的無煙煤屬國家稀缺煤種，經(jīng)洗選加工后方可作為噴吹煤、化工用煤。如果不進行洗選加工而僅靠售賣原煤，則煤質(zhì)無法保證，影響商品煤銷售，極大地降低經(jīng)濟效益，也不符合國家煤炭資源利用政策。建成洗煤廠后對煤炭進行洗選加工，洗選產(chǎn)品就地地銷，可以充分發(fā)揮汽車或火車運能，矸石可用于矸石電廠、磚廠或直接就地回填處理，減少矸石的無效運輸。根據(jù)當(dāng)前市場行情可知，原煤經(jīng)洗選加工后作為噴吹煤及化工用煤將帶來顯著的經(jīng)濟效益。綜上所述，新建一座選煤廠是十分必要的。

1選煤廠基本情況

山西焦煤山煤國際鹿臺山煤業(yè)有限公司選煤廠服務(wù)于山煤集團鹿臺山煤礦，是礦井型選煤廠。建設(shè)規(guī)模0.90Mt/a，工作制度為每年工作330d，每日工作16h，每日處理原煤2727.27t，每小時處理原煤170.45t。選煤廠位于現(xiàn)有工業(yè)廣場內(nèi)，主場建設(shè)場地位于現(xiàn)有生產(chǎn)系統(tǒng)西側(cè)預(yù)留空地，消防、生產(chǎn)用水水源均由礦井統(tǒng)一考慮。礦井可提供的水質(zhì)、水量能夠滿足選煤廠建設(shè)的需要。現(xiàn)有消防、生產(chǎn)給水管網(wǎng)滿足所需水量、水壓要求。本次新增人員利用現(xiàn)有生活用水設(shè)施，不增加生活給水管網(wǎng)。生活用水1.75m3/d，生產(chǎn)補加水218.18m3/d（0.08m3/t入洗量），一次火災(zāi)消防用水291.6m3。礦井已有一座鍋爐房，鍋爐房內(nèi)預(yù)留有一臺鍋爐的安裝位置。本次設(shè)計在已有鍋爐房內(nèi)增加一臺熱水鍋爐，新增建（構(gòu)）筑物采暖管路取自已有的供熱管網(wǎng)。已有管網(wǎng)能夠滿足本工程所需的負(fù)荷要求。煤倉均采用散熱器供暖方式，供暖熱媒為鍋爐房提供的95°C/70°C熱水。為排除余熱、余濕，主廠房除采用自然通風(fēng)外，還設(shè)置了屋頂風(fēng)機強制通風(fēng)換氣。所有原煤轉(zhuǎn)運皮帶、二次揚塵及皮帶受料點處均設(shè)置噴霧抑塵裝置，以減少煤塵的產(chǎn)生。除采用噴霧降塵設(shè)施外，還設(shè)置了軸流風(fēng)機強制通風(fēng)，改善現(xiàn)場工作環(huán)境。本工程在主廠房旁設(shè)低壓配電室，電源引自現(xiàn)有礦井變電所10kV母線段，在現(xiàn)有礦井變電所內(nèi)新增一臺10kV高壓柜作為配出電源柜。采用單根ZR-YJV22-10kV3×70mm2阻燃交聯(lián)聚乙烯鎧裝電纜直埋敷設(shè)至主廠房配電室。礦井變電所的負(fù)荷余量可以滿足選煤廠的建設(shè)需要。山西焦煤山煤集團鹿臺山煤業(yè)有限公司位于沁水縣西南14km處張村鄉(xiāng)馮村附近，行政區(qū)劃隸屬張村鄉(xiāng)管轄。該礦區(qū)西部緊鄰張村鄉(xiāng)至沁水縣城的縣級公路，可達(dá)沁水縣城，與侯馬—晉城二級公路相接，同時可達(dá)侯馬—月山鐵路線沁水火車站，交通十分便利。項目總造價為3.22068×107元，噸煤投資為35.79元，其中，土建工程投資為1.05592×107元，設(shè)備及工器具購置投資為0.82581×107元，安裝工程投資為0.69364×107元，工程建設(shè)其他費用投資為0.46301×107元，工程預(yù)備費投資為0.18230×107元。

2工藝流程設(shè)計本廠的選煤方法為：0～50mm無壓三產(chǎn)品重介分選，0.25～1.00mm粗煤泥TCS（智能粗煤泥分選機）分選，0～0.25mm細(xì)煤泥濃縮壓濾脫水回收。工藝流程分為原煤準(zhǔn)備系統(tǒng)、主選系統(tǒng)、粗煤泥分選系統(tǒng)、細(xì)煤泥回收系統(tǒng)、介質(zhì)系統(tǒng)等。

2.1原煤準(zhǔn)備系統(tǒng)本礦井已經(jīng)建有原煤篩分系統(tǒng)，篩分粒度為50mm。+50mm原煤進入塊煤分選系統(tǒng)處理（不在本工程范圍內(nèi)），-50mm原煤經(jīng)倉儲后進入主選系統(tǒng)分選。

2.2主選系統(tǒng)原煤（0～50mm）不脫泥，直接進入無壓三產(chǎn)品分選，溢流經(jīng)脫介、脫水、分級，產(chǎn)生+25mm塊精煤和1～25mm末精煤，1～25mm末精煤再經(jīng)離心機脫水成為噴吹煤（或動力煤）產(chǎn)品；中煤經(jīng)脫介、脫水、分級，其中，+25mm塊中煤與塊精煤混合后進入現(xiàn)有方倉儲存，1～25mm末中煤再經(jīng)離心機脫水成為動力煤產(chǎn)品；底流經(jīng)脫介、脫水后成為矸石產(chǎn)品。

2.3粗煤泥分選系統(tǒng)主選系統(tǒng)脫介產(chǎn)生的稀介質(zhì)及分流的合格介質(zhì)經(jīng)磁選機磁選，磁選尾礦經(jīng)煤泥濃縮分級旋流器分級，底流（0.25～1.00mm）粗煤泥進入TCS分選，溢流經(jīng)弧形篩、煤泥離心機脫水后，粗精煤泥與主選系統(tǒng)末精煤（1～25mm）混合成為噴吹煤（或動力煤）產(chǎn)品，TCS底流經(jīng)高頻篩脫水后與重介矸石一起進入矸石倉。

2.4細(xì)煤泥回收系統(tǒng)煤泥濃縮分級旋流器溢流、弧形篩篩下水匯集后，進入濃縮機澄清、濃縮，濃縮機底流泵入壓濾機脫水，壓濾煤泥單獨作為產(chǎn)品銷售，壓濾機濾液返回濃縮機澄清，濃縮機溢流作為澄清水循環(huán)使用。

2.5介質(zhì)系統(tǒng)主選系統(tǒng)溢流、中流、底流經(jīng)弧形篩、直線篩脫介產(chǎn)生的合格介質(zhì)返回合格介質(zhì)桶循環(huán)使用，稀介質(zhì)進入磁選機磁選后，精礦返回合格介質(zhì)桶循環(huán)使用。外購磁鐵礦粉加水?dāng)嚢杌靹蚝螅杉咏楸么蛉牒细窠橘|(zhì)桶（或稀介桶），完成介質(zhì)補加，及時補充產(chǎn)品帶走的磁鐵礦粉或磁選尾礦損失的磁鐵礦粉，以維持介質(zhì)系統(tǒng)的平衡及分選密度的穩(wěn)定。

3主要設(shè)備選型

3.1設(shè)備選型原則選煤廠生產(chǎn)系統(tǒng)是“流水線”式作業(yè)，設(shè)備選型必須全盤考慮，實現(xiàn)全廠設(shè)備的整體配套和可靠，防止“木桶效應(yīng)”影響全套系統(tǒng)的可靠性。據(jù)此并依招標(biāo)文件的要求，本工程設(shè)備選型以先進、可靠、經(jīng)濟、合理為原則。主要洗選設(shè)備及生產(chǎn)輔助設(shè)備的關(guān)鍵部件選用進口組裝，其他設(shè)備采用國內(nèi)知名廠家先進可靠的設(shè)備；所有設(shè)備盡可能選用規(guī)模和系統(tǒng)能力相配套的大型設(shè)備，以簡化系統(tǒng)、方便管理。同類設(shè)備及大型部件（包括電動機、減速器、液力耦合器、泵類）盡量采用一種規(guī)格，減少不同規(guī)格的數(shù)量，以減少備品備件種類；在保證設(shè)備性能的前提下，其規(guī)格型號、制造廠家和技術(shù)特征的選擇盡量考慮其通用性和一致性。同類設(shè)備選擇同一制造廠家，以減少備品備件種類和降低采購管理難度。

3.2主要設(shè)備選型確定無壓三產(chǎn)品重介旋流器選用一段直徑900mm、二段直徑650mm的國產(chǎn)優(yōu)質(zhì)產(chǎn)品。該設(shè)備分選精度高，處理能力強，運行平穩(wěn)。精煤、中矸脫介篩均選用3073型直線篩，其中，中矸脫介篩采用雙通道設(shè)計，兩臺設(shè)備型號統(tǒng)一的備件可互換，結(jié)構(gòu)合理，可以實現(xiàn)設(shè)備大型化，具有處理能力強，分級、脫介效果好，生產(chǎn)穩(wěn)定等特點[9-10]。精煤和中煤離心機分別選用國產(chǎn)Φ1200mm和Φ900mm的立式離心脫水機，其優(yōu)點在于物料物理水分少，入料上限大，設(shè)備驅(qū)動、齒輪和軸承均避開了漿料，防止?jié){料損壞這些部件。維修時不需要全部拆除離心機，維修方便。煤泥離心機選用Φ1200mm的立式離心脫水機，該設(shè)備處理能力強，產(chǎn)品水分少，使用效果好。磁選機選用美國藝?yán)窘M裝設(shè)備，1219mm×2972mm型，背靠背布置，該設(shè)備采用當(dāng)前最先進的磁路設(shè)計，用最合理的筒槽布置，以使重介中的磁鐵礦粉得到最大程度的回收。粗煤泥分選機采用TCS，要求能夠?qū)崿F(xiàn)底流有動力連續(xù)穩(wěn)定排料。依據(jù)調(diào)控分選密度的需要，可以對底流排料量實施連續(xù)數(shù)字化控制，最小可以排到零，也可以調(diào)控足夠小的底流排料量并連續(xù)生產(chǎn)。TCS的入料、底流、頂水和補水配備進口流量計，對入料、頂水、底流、溢流流量實時監(jiān)控。配套專用頂水泵及變頻器，泵的開停由集控系統(tǒng)控制。壓濾機采用國內(nèi)先進的隔膜快開式壓濾機，過濾面積S=800m2，該設(shè)備運行平穩(wěn)可靠，耗電量低，全過程自動控制，隔膜壓榨，使壓榨后的濾餅含濕率降到28%以內(nèi)。

3.3工業(yè)控制系統(tǒng)設(shè)備選型選煤廠控制系統(tǒng)范圍為從原煤倉至1號轉(zhuǎn)載點帶式輸送機開始至筒倉上末精煤皮帶及方倉上全部新增的電氣設(shè)備。控制系統(tǒng)采用西門子或歐姆龍PLC（可編程邏輯控制器）。在主廠房配電室設(shè)置控制主站及分站，該控制系統(tǒng)可以對主廠房、濃縮車間、介質(zhì)庫、1號轉(zhuǎn)載點、煤泥卸載點、現(xiàn)有方倉改造及相關(guān)棧橋的全部電氣設(shè)備進行控制。選煤廠集控室設(shè)置在主廠房配電室。上位機與控制系統(tǒng)的PLC之間采用工業(yè)以太網(wǎng)方式通信，通過運行組態(tài)軟件實現(xiàn)對全廠范圍內(nèi)設(shè)備的監(jiān)控。在選煤廠集控室內(nèi)設(shè)置工控機1臺（采用研華工控機CPU2.0G、4G內(nèi)存、500G硬盤，配備24英寸液晶顯示器），同時配置1臺A4多功能激光打印機。

4選煤工藝布置

4.1布置原則布置總體格局要與地形地貌、風(fēng)向條件緊密結(jié)合，統(tǒng)籌兼顧，因地制宜，并留有場內(nèi)運輸空間，布置緊湊，節(jié)約用地。根據(jù)整個區(qū)域場地的設(shè)計標(biāo)高和規(guī)劃廠區(qū)道路情況，合理地確定工業(yè)場地場坪標(biāo)高，以減少土方工程量。結(jié)合工藝流程布置，做到功能分區(qū)明確，場地布置緊湊。廠前區(qū)開闊，檢修通道合理。在滿足工藝布置和交通運輸合理的前提下，力求人貨分流、路徑短捷、作業(yè)方便，減少相互交叉和折返運輸，布置美觀大方。總平面布置充分結(jié)合現(xiàn)有場地條件及現(xiàn)有地面生產(chǎn)設(shè)施的布置情況，合理規(guī)劃，盡量不影響現(xiàn)有地面生產(chǎn)設(shè)施。主要車間工藝布置合理，空間利用率高，生產(chǎn)管理方便，檢修操作空間適當(dāng)，各系統(tǒng)搭配合理簡捷，工藝調(diào)整控制靈活順暢。

4.2車間布置鹿臺山煤礦工業(yè)場地現(xiàn)有3座Φ15m筒倉，本次工程將最西側(cè)筒倉改造為原煤倉，將原煤倉下原有車道封閉，倉下給煤機溜槽延長進入新增的原煤皮帶。倉上設(shè)施利用現(xiàn)有的。主廠房的結(jié)構(gòu)形式為鋼筋砼框架結(jié)構(gòu)，單獨基礎(chǔ)。廠房內(nèi)設(shè)有重介洗選系統(tǒng)、粗煤泥分選回收系統(tǒng)、細(xì)煤泥壓濾回收系統(tǒng)、介質(zhì)系統(tǒng)及清掃水系統(tǒng)。主廠房車間主要分為四層進行布置，各層布置情況簡述如下：在廠房一層主要布置有合介桶、稀介桶、煤泥水桶及對應(yīng)的泵，以及末精煤離心機、末中煤離心機、粗煤泥離心機，產(chǎn)品皮帶從廠房負(fù)一層出廠，另濃縮機的底流泵、循環(huán)水泵以及TCS頂水泵布置在廠房一層，空壓機房布置于廠房底層；廠房二層主要布置有精煤脫介篩、中矸脫介篩、壓濾煤泥收集刮板、振動弧形篩；廠房三層主要布置有三產(chǎn)品重介旋流器、filter press、磁選機、TCS尾礦高頻篩以及TCS；廠房的頂層布置有塊原煤入洗皮帶機頭、分級旋流器組以及消防水箱。主廠房整個車間內(nèi)布置有封閉樓梯間和提升孔，在車間內(nèi)布置有5t的電動葫蘆，負(fù)責(zé)主廠房內(nèi)設(shè)備的檢修。采用1座Φ18m的雙層混凝土濃縮池，上層為濃縮池，下層為事故放料池。靠近濃縮池設(shè)置有入料緩沖箱及循環(huán)水池。濃縮機底流泵及澄清水泵、TCS頂水泵布置在主廠房內(nèi)底層靠近濃縮車間的一側(cè)，在濃縮池下層的事故水池內(nèi)布置有1臺事故池回水泵。現(xiàn)有3座筒倉，除最西側(cè)筒倉作為原煤倉外，東側(cè)2座筒倉仍作為產(chǎn)品煤倉。經(jīng)分選的末精煤由出廠皮帶進入現(xiàn)有篩分樓運至筒倉小塊皮帶，再運輸至現(xiàn)有筒倉儲存。現(xiàn)有6座8m×8m方倉經(jīng)重新規(guī)劃用來儲存+50mm塊煤、25～50mm中塊煤、-25mm篩限下及中煤、矸石。方倉頂部增加2層用來布置產(chǎn)品膠帶輸送機的驅(qū)動裝置。塊煤溜槽采取設(shè)置緩沖臺等防碎措施，避免塊煤落倉時摔碎。

5結(jié)語根據(jù)山西焦煤山煤國際鹿臺山煤業(yè)有限公司的實際情況，對新建選煤廠進行了設(shè)計，主要包括工藝流程設(shè)計、主要設(shè)備選型以及選煤工藝布置。工藝流程分為原煤準(zhǔn)備系統(tǒng)、主選系統(tǒng)、粗煤泥分選系統(tǒng)、細(xì)煤泥回收系統(tǒng)、介質(zhì)系統(tǒng)等。無壓三產(chǎn)品重介旋流器選用一段直徑900mm、二段直徑650mm的國產(chǎn)優(yōu)質(zhì)產(chǎn)品。磁選機選用美國藝?yán)窘M裝設(shè)備。主廠房的結(jié)構(gòu)形式為鋼筋砼框架結(jié)構(gòu)，單獨基礎(chǔ)。廠房內(nèi)設(shè)有重介洗選系統(tǒng)、粗煤泥分選回收系統(tǒng)、細(xì)煤泥壓濾回收系統(tǒng)、介質(zhì)系統(tǒng)及清掃水系統(tǒng)。

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1煤用壓濾機的基本要求和特征

（１）設(shè) 備 大 型 化。采 用 大 型 濾 板 和 短 配 置 不 僅可 以 減 少 占 地，同時由于濾板組件變短導(dǎo)致壓差傳遞 次 數(shù) 減 少，壓 差 容 易 被 阻 斷，在 增 加 處 理 量 的 同時還可以減少因成餅不均勻所產(chǎn)生的危險壓差。快開式壓濾機在濾板組件中間增加了金屬驅(qū)動板，可徹 底 阻 斷 壓 差 的 傳 遞，延長濾板和整個壓濾機的壽 命。

（２）運 行 快 速 化。要 求 壓 濾 機 入 料 快、排 液快、卸 餅 快 以 及 更 換 濾 布 快，這就有利于大型壓濾機 采 用 多 端 口 入 料、明 暗 流 同 時 排 液、過 濾 面 設(shè) 計優(yōu) 化、縮短隔膜擠壓技術(shù)的過濾周期以及帶入料靴的 板 布 分 離 結(jié) 構(gòu) 等 措 施 的 實 現(xiàn)。而對于特大型的壓濾 機，采用高位槽入料法更為合適。在 過 濾 初 期，選用高位自流的方法向壓濾機無障礙入料，實 現(xiàn) 快速 過 濾，無 需 進 料 泵 可 以 大 大 節(jié) 省 能 耗；過 濾 后 期則 采 用 小 流 量 高 壓 泵，可 降 低 成 本。

（３）系 統(tǒng) 可 靠 性。在 使 用 壓 濾 機 時，除 了 要 求液 壓 系 統(tǒng)、拉 板 系 統(tǒng)、洗布系統(tǒng)和集液翻板系統(tǒng)等可 靠 之 外，及時知道濾布的損壞情況和發(fā)現(xiàn)損壞濾布的確切位置對整個工藝的穩(wěn)定運行也是非常重要的。將德國連恩舍過濾有限公司發(fā)明的三通取樣閥應(yīng) 用 到 壓 濾 機 中，可以在不影響工藝流程的情況下，精 確 發(fā) 現(xiàn) 損 壞 濾 布 的 確 切 位 置，避 免 濾 布 損 壞帶 來 的 一 系 列 問 題。

２煤 用 壓 濾 機 及 濾 板 選 擇

２．１廂 式 壓 濾 機廂式壓濾機主要依靠入料泵提供的液壓驅(qū)動力進 行 脫 水，懸 浮 液 泵 入 壓 濾 機 后，首先在濾腔兩側(cè)的濾 布 表 面 形 成 濾 餅，然后不斷向濾腔中間增厚。連續(xù)液相的存在是保持液壓驅(qū)動力的前提，所 以 濾餅 中 心 始 終 存 在 一 個 濃 度 高 于 入 料 濃 度、并 以 液 體為 連 續(xù) 相 的 固 液 混 合 體，俗 稱“囊 心”。“囊 心”的大 小 與 煤 泥 的 性 質(zhì)（如 顆 粒 大 小、灰 分、泥 化 程 度等）有 著 很 大 的 關(guān) 系。“囊 心”的 存 在 會 影 響 濾 餅的 水 分，并 阻 礙 卸 餅。對 于 相 同 的 煤 泥，采 用 高 壓入 料 可 減 小“囊 心”的 存 在，然而提高入料的壓力在 很 大 程 度 上 會 導(dǎo) 致 危 險 壓 差 的 出 現(xiàn)。現(xiàn) 有 兩 個 途 徑 可 以 減 少 危 險 壓 差 出 現(xiàn) 的 幾 率，一 是 通 過 增 加 濾 板 基 板 的 厚 度，二是通過增加濾板支 撐 凸 臺 的 數(shù) 量 或 直 徑。選 擇 壓 力 時，通 常 要 考 慮濾 板 的 承 壓，目前濾板的壓力等級分為０．８ＭＰａ、１．６ＭＰａ和 更 高 壓 力３個 額 定 壓 力 檔 次。這 些 等 級均 是 在 常 溫 下 進 行 分 類 定 義 的，忽略了溫度對濾板承 壓 能 力 的 影 響。

２．２隔 膜 壓 濾 機與廂式壓濾機的區(qū)別在于隔膜壓濾機中濾板有２個 可 前 后 移 動 的 過 濾 面（隔 膜），當(dāng) 過 濾 工 序 完成 后，在隔膜與基板之間形成的擠壓腔中，通 入 擠壓 介 質(zhì)（如 壓 縮 空 氣 或 液 體），可對濾餅進行二次擠 壓，使 得“囊 心”在二次擠壓的作用下均勻脫水，形成含水率更低和更加均勻的濾餅。由 于 隔 膜濾板擠壓的壓力與相鄰的隔膜濾板的工作壓力相等，二者壓力可以相互抵消，所 以 隔 膜 濾 板 即 使 在更高的二次擠壓作用下對濾餅進行深度脫水時也不會 形 成 壓 差，不 會 造 成 濾 板 的 基 板 變 形。一 般 情 況 下，隔膜濾板的擠壓介質(zhì)采用壓縮空氣 或 不 可 壓 縮 液 體（例 如 水）。當(dāng) 擠 壓 壓 力 低 于０．８ＭＰａ時，選 用 壓 縮 空 氣 較 多，主 要 原 因 是 由于０．８ＭＰａ的 空 壓 機 價 格 相 對 低 廉，選 擇 余 地 大，而且壓縮空氣單元的控制系統(tǒng)簡單且成本較低；當(dāng)擠 壓 壓 力 大 于１．６ＭＰａ，使 用 壓 縮 空 氣 作 為 擠 壓 介質(zhì)的安全隱患較大，為 了 安 全 考 慮，不 可 壓 縮 液 體成 為 首 選。但是使用不可壓縮流體作為擠壓介質(zhì)時也 有 一 個 缺 點，特 別 是 在 高 壓 擠 壓 完 成 前，由 于 濾餅的壓縮性近乎消失，擠 壓 壓 力 會 迅 速 升 高，為 了控 制 壓 力，設(shè) 計 的 壓 榨 單 元 較 為 復(fù) 雜，成 本 較 高。

２．３干 燥 壓 濾 機隨著對濾餅含水率的要求越來越低，僅靠提高隔膜擠壓壓力這種機械脫水方法已經(jīng)很難達(dá)到要求，此時干燥壓濾機應(yīng)運而生。干燥壓濾機是將隔膜壓濾機和熱力干燥合二為一的一種設(shè)備，某些情況下可以將濾餅水分脫至１％以下，干燥壓濾機由機架、干 燥 濾 板（混 合 組 件）、加熱系統(tǒng)以及真空冷凝等系統(tǒng)組成。干燥濾板組中的隔膜濾板不作任何改變，而 其 中 廂式濾板的材料換成了導(dǎo)熱系數(shù)更高的金屬材料。由于 聚 丙 烯 隔 膜 濾 板 的 最 大 工 作 溫 度 為１００°C，為 了提高干燥的溫差驅(qū)動力，通 常 采 用 真 空 泵 將 過 濾 腔室 抽 至－１０～－２０ｋＰａ的 真 空 狀 態(tài)，降 低 濾 液 的沸 點。同 時 采 用 加 熱 系 統(tǒng) 循 環(huán) 加 熱 水 至８０°C～９５°C，并從下端將水泵入干燥濾板，帶 盤 形 的 熱 水 流道的干燥濾板，以 保 證 干 燥 板 處 于 較 高 的 傳熱 溫 度，并 采 用 熱 力 學(xué) 的 方 法 降 低 濾 餅 水 分。在 干燥 階 段，必 須 保 持 隔 膜 處 于 擠 壓 狀 態(tài)，保 證 濾 餅 始終完全緊貼干燥濾板，沒 有 空 氣 縫 隙，保 證 傳 熱 效率。如果隔膜沒有對濾餅進行擠壓，就 會 隨 著 不 斷脫水 而 收 縮 變 薄，濾餅則有可能與干燥濾板脫離，導(dǎo)致濾餅處于懸空狀態(tài)，干 燥 并 不 充 分。所 以 干 燥時，壓濾機必須處于擠壓、加 熱、真 空 三 者 同 時 工作 的 狀 態(tài)。

２．４濾板與壓濾機的壓緊力當(dāng)濾板組件在壓濾機中壓緊時，塑 料 的 濾 板 及濾 布 會 被 壓 縮，并且操作溫度的變化也會造成濾板及濾布材料的熱膨脹和冷收縮。由 于 有 很 大 的 伸 縮量，所 以 壓 緊 力 在 長 度 方 向 上 應(yīng) 有 伸 縮 的 補 償 功能，這個伸縮補償功能主要由壓濾機的壓緊裝置來完 成。壓濾機的壓緊裝置所產(chǎn)生的壓力不僅要抵消過 濾 壓 力 和 擠 壓 壓 力，而且還必須保證過濾腔室的密 封 性，所 以 在 壓 濾 機 工 作 時，必須保證有一個有效的 最 小 壓 緊 力Ｆｍｉｎ，同時為了防止濾板的永久變形 和 機 架 的 過 載 損 壞，根據(jù)操作壓力和溫度的不同，必 須 將 壓 緊 力 限 制 在 最 大 壓 緊 力Ｆｍａｘ以 下。壓濾機的操作壓緊力必須介于Ｆｍｉｎ和Ｆｍａｘ之 間。壓 緊力 太 小，會 導(dǎo) 致 板 間 漏 液，物 料 擠 出，而 極 端 情 況下 會 導(dǎo) 致 設(shè) 備 損 壞，還有可能影響人身安全。

濾 布 的 選 擇從 材 質(zhì) 上 講，聚丙烯的使用范圍最廣，耐 酸 堿性 優(yōu) 良，而且在市場上作為可選的透氣率范圍也最廣；尼 龍 濾 布 有 更 好 的 耐 磨 蝕 性 能，所 以 在 煤 泥 和精 煤 過 濾 中，一 般 尼 龍 布 作 為 首 選；滌 綸 布 則 能 在１５０°C的 溫 度 下 工 作，當(dāng) 然ＰＥＥＫ的 耐 溫 性 更 好，可 以 達(dá) 到２００°C。一般情況下精煤過濾的濾布透氣率 在６００～７００Ｌ／ｍ２·ｓ，而 原 生 煤 泥 則 選 用 透 氣率 在２５０～４００Ｌ／ｍ２·ｓ的 單 絲 尼 龍 濾 布。在 濾 布背 面 安 裝 大 透 氣 率 的 底 布，可延長濾布的壽命１０％～２５％。對濾布做砑光處理可以減小其與濾餅的 實 際 接 觸 面 積，從而降低濾餅在濾布上的附著力，有 利 于 自 動 卸 餅，同時砑光處理還可以將濾布的 透 氣 率 向 下 做 一 些 調(diào) 整。然而盡管過度的砑光處理 可 以 使 濾 布 的 表 面 更 加 光 滑，但對濾布的強度和壽 命 明 顯 有 害。

結(jié) 語

壓濾機作為煤泥水處理系統(tǒng)的把關(guān)設(shè)備，必 須具 有 設(shè) 備 大 型 化、運行快速化和系統(tǒng)穩(wěn)定可靠等基本 特 征。隨著對泥餅含水率越來越低的要求，對 煤用 壓 濾 機 的 要 求 也 逐 步 提 高，干燥壓濾機應(yīng)運而生并 逐 漸 在 煤 泥 脫 水 中 推 廣 應(yīng) 用。濾板是壓濾機的核心 部 件，過 濾 中 起 到 非 常 重 要 的 作 用，因 此 選 擇 濾板 時，一定要綜合考慮溫度和壓力的影響。正 確 的壓緊力是保證壓濾機系統(tǒng)正常工作和使用壽命的一個 前 提，尼龍單絲濾布是煤礦用壓濾機的首選。

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煤泥脫水一直是選煤廠的關(guān)鍵工序，壓濾機是選煤廠最重要的機械設(shè)備，其作用首先是將固液進行完全意義上的分離，保證在分離之后還能回收利用，最終達(dá)到降低濾餅中含水量的要求。目前應(yīng)用的加壓過濾技術(shù)是世界上先進脫水技術(shù)之一，將過濾機置于封閉的加壓倉內(nèi)，通過在加壓倉內(nèi)充入加壓空氣，僅通過空氣壓力作用和離心原理實現(xiàn)物料的脫水分離，使用壓縮空氣和物料的密度進行脫水，脫水效果好，脫水成本較低。國內(nèi)大多數(shù)選煤廠使用的壓濾機，此類壓濾機長時間使用后，已逐步暴露出脫水工藝方面的許多問題:壓濾后產(chǎn)品含水率較高、脫水設(shè)備故障率高、運行成本較高等。筆者通對選煤廠傳統(tǒng)脫水工藝的分析，基于壓濾機的基本結(jié)構(gòu)特點和原理，針對當(dāng)前脫水工藝和設(shè)備存在的問題提出了優(yōu)化改進方案，通過實踐應(yīng)用表明，該套脫水工藝技術(shù)脫水效果明顯，降低了產(chǎn)品含水量，取得了良好的應(yīng)用效果。

1傳統(tǒng)壓濾脫水工藝技術(shù)與設(shè)備

1．1傳統(tǒng)filter press脫水工藝技術(shù)概述壓濾脫水工藝是選煤廠生產(chǎn)過程中關(guān)鍵環(huán)節(jié)，主要是利用泵和壓縮空氣(利用空壓機提供空氣) ，將固液將固液兩相組成的礦漿在壓力差的作用下，將液體從固體中析出，實現(xiàn)固液的兩相分離，從而將固體中的水分進行分離。壓濾機脫水工藝系統(tǒng)組成如圖1。

圖中，通過空氣壓縮機16提供動力源，通過電控系統(tǒng)對各個環(huán)節(jié)進行控制，將壓濾機最終提取出的水用于再次循環(huán)利用，整個動作過程是由自動控制系統(tǒng)實現(xiàn)。核心是采用壓縮空氣作為給料系統(tǒng)的動力來源，一方面空氣動力可以取之不盡，另一方面采用空氣動力不會對環(huán)境造成污染，速度更快，通過壓濾機可得到循環(huán)水進行再次利用。傳統(tǒng)的壓濾脫水工藝技術(shù)主要是采用壓力差進行固液分離，存在分離不徹底的問題，在固體中摻雜有少量的液體無法全部排出，所以最終會影響脫水后的煤粉質(zhì)量。

1．2壓濾機結(jié)構(gòu)與工作原理壓濾機是選煤脫水工藝中保證最終產(chǎn)品含水率和產(chǎn)品質(zhì)量的最關(guān)鍵機械設(shè)備，目前國內(nèi)在加壓過濾系統(tǒng)中采用的壓濾機。主要 由 濾 板、液 壓 系 統(tǒng)、壓 濾 機 框、濾 板傳輸系統(tǒng)和電控系統(tǒng)等幾部分組成。圖2所示為壓濾機設(shè)備基本結(jié)構(gòu)組成圖。

壓濾機在加壓過濾中是通過加壓將固液進行分離，將煤泥轉(zhuǎn)變?yōu)闉V餅。通過將煤泥初步的擠壓將內(nèi)部的水排出，濾漿在進料泵的推動下，通過止推板進入各個濾室內(nèi)利用壓力作用實現(xiàn)固液分離。利用空氣壓縮機產(chǎn)生較大壓力的空氣，通過強大的空氣流將壓濾后的煤餅中細(xì)小的空氣帶出，最終得到較為干燥的煤餅。但是現(xiàn)有的壓濾系統(tǒng)在實際運行過程中，存在間隙較大 的 問 題，由此得到的產(chǎn)品自身含水量較高，且部分產(chǎn)品受到的空氣壓力不均勻。

2脫水工藝技術(shù)優(yōu)化方案通過對現(xiàn)有壓濾脫水工藝和設(shè)備特點進行分析得出，目前壓濾工藝技術(shù)和設(shè)備存在的問題主要有以下幾點:

①Coal Preparation Plant Filter Press脫水設(shè)備長時間運行導(dǎo)致零部件磨損比較嚴(yán)重，故障頻頻發(fā)生，故障率比較高;

②壓濾脫水效果不好，產(chǎn)品含有水分比較大，導(dǎo)致產(chǎn)品在實際輸送過程中損失較大;

③傳統(tǒng)壓濾機需要頻繁更換使用過濾網(wǎng)等部件，設(shè)備運行成本較高。針對當(dāng)前壓濾機脫水工藝技術(shù)存在的問題，結(jié)合企業(yè)實際生產(chǎn)中對壓濾機脫水工藝改進和優(yōu)化的需求，提出了脫水工藝技術(shù)優(yōu)化方案，主要從風(fēng)能角度、濾布材料和入料工藝等方面進行了優(yōu)化，具體重點和效果主要如下所述。

(1)降低風(fēng)能損耗。采用空氣壓縮機作為動力源，風(fēng)管與過濾板之間的距離將會影響脫水效果，距離越近，對于水分的排出越有利。針對壓濾機而言，中部的濾板距離風(fēng)管的位置比較遠(yuǎn)，當(dāng)風(fēng)傳輸?shù)焦艿乐虚g位置時，風(fēng)力相對會比較弱，此時浮煤中的水分無法得到有效排出。針對此問題，需要均衡濾板的過濾效果，減少兩側(cè)的濾板排水孔數(shù)量，高風(fēng)壓的損耗會有所降低，可有效降低風(fēng)能損耗。改 進 傳 統(tǒng) 的 工藝，實現(xiàn)吹風(fēng)和壓濾兩個工序同時進行，可以有效改善壓濾機 脫 水 效 果，提 高 透 水 透 氣 性，降 低 水 分 的含量。

(2)定期更換濾布材質(zhì)。濾布是保證壓濾機過濾效果的重要環(huán)節(jié)，設(shè)備在最初運行時采用廠家標(biāo)配的復(fù)合型濾布，這種濾布受自身材質(zhì)影響，當(dāng)煤粉經(jīng)過時容易引 起 粘 煤，長時間運行出現(xiàn)壓濾不嚴(yán)實情況，對于排出水分很不利。所以需要及時更換濾布，單絲濾布可以解決壓濾不緊實的情況，單絲濾布在性能上可以實現(xiàn)復(fù)合濾布的所有功能，更容易清洗，濾布不容易被堵塞，能夠起到良好的過濾效果。

(3)優(yōu)化入料工藝。目前壓濾機是一次兩側(cè)入料，在完成一次入料后受到濾餅自身結(jié)構(gòu)影響，整體透水性能不佳，采用傳統(tǒng)兩側(cè)入料形式會導(dǎo)致部分殘留物料留在入料孔內(nèi)，無法實現(xiàn)清空，最后在卸料時會帶入殘留物料影響精煤含水量。改進傳統(tǒng)入料工藝，單側(cè)入料，多次入料，兩次壓榨，一方面可以提高精煤的質(zhì)量，同時也會在兩層粗顆粒之間形成透水層，降低積孔內(nèi)的殘料，可以更好地進行水分過濾，提高壓濾效率，保證最終精煤的質(zhì)量。(4)混合攪拌，均勻入料。傳統(tǒng)的入料方式，不考慮物料的粒度，粗細(xì)顆粒之間分配比例不均勻，直接進入精煤池后相同質(zhì)量的樣本含有的水分存在差異。為此，可以利用空氣壓縮機提供動力，增加攪拌裝置，將入料的粗細(xì)顆粒攪拌均勻，通過以上工藝設(shè)計和優(yōu)化，可以保持最終精煤含水量在一個相對可控的穩(wěn)定范圍內(nèi)，提高精煤的產(chǎn)量和質(zhì)量。

3應(yīng)用效果對比分析針對傳統(tǒng)選煤廠壓濾機脫水工藝問題，其中重點對入料、濾布和攪拌裝置等方面進行調(diào)整優(yōu)化，通過實施以上優(yōu)化方案，解決了最終精煤含水量較高，產(chǎn)品質(zhì)量不穩(wěn)定的問題。對比工藝優(yōu)化前后設(shè)備運行情況實驗數(shù)據(jù)得到如表1所列的分析結(jié)果。通過分別使用2臺編號1號和編號2壓濾機，統(tǒng)計改造前、后的精煤水分含量檢測5組數(shù)據(jù)，最后求平均值，優(yōu)化后壓濾機的精煤水分含量明顯降低，對2臺壓濾機進行10次檢測均得到了相同的結(jié)果，平值中也可以得出1號壓濾機在優(yōu)化前為26．4%，優(yōu)化后變?yōu)?9．6%，精煤含水量差值為6．8%，精煤的水分含量高品質(zhì)精煤的含水要求，取得良好的應(yīng)用效果。

4結(jié)語針對選煤廠傳統(tǒng)加壓過濾系統(tǒng)差、含水量高、脫水效果差等問題，通過壓濾機脫水工藝技術(shù)和設(shè)備應(yīng)用實踐，提出壓濾機脫水工藝技術(shù)優(yōu)化方案，包括降低風(fēng)能損耗、定期更換濾布材質(zhì)、優(yōu)化入料工藝和次數(shù)等方法。采用2臺壓濾機、單臺設(shè)備實測10組數(shù)據(jù)，對比分析了脫水工藝技術(shù)優(yōu)化前、后的精煤含水量，結(jié)果表明采用優(yōu)化后的方案，精煤的含水量明顯降低，產(chǎn)出的精煤能夠滿足質(zhì)量要求，同時，也驗證了工藝技術(shù)優(yōu)化方案的正確性，對于提高選煤廠的精煤產(chǎn)量和質(zhì)量具有重要的參考價值和意義。

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