what is a colloid mill

The colloid mill consists of stainless steel, semi-stainless steel colloid mill; the basic principle is through the high-speed relative linkage between the fixed teeth and moving teeth. In addition to the motor and some parts, all parts in contact with the material are high-strength stainless steel. The critical dynamic and static grinding discs are strengthened to have good corrosion and wear resistance so that the processed material is pollution-free and pure.

Structure

Colloid mill is several patented products: compact design, practical new type, beautiful appearance, good sealing, stable performance, convenient operation, simple decoration, durable, adaptable to a wide range, and high production efficiency; it is the ideal processing equipment to deal with fine materials. In addition to the motor and some parts, all parts in contact with the material are high-strength stainless steel. The critical dynamic and static grinding discs are strengthened, so it has good corrosion resistance and wears resistance so that the processed material is pollution-free and pure.

Processing state: multi-stage online emulsification disperser

Equipment function: online type, dispersion, emulsification, sanitary grade

Features

1. three-stage online dispersion emulsifier

2. three-stage fixed rotor form: 2G (coarse) 4M (medium) 6F (fine)

3. Perfect for stable homogeneous emulsions and suspensions

4. Dispersing head can be freely assembled, modular, and easy to maintain

5. Concentrated particle size distribution with only one treatment

6. Infinitely adjustable speed (frequency converter)

7. All materials in contact with the material are SS316

8. Meet CIP/SIP cleaning standards, suitable for food and pharmaceutical production

9. 3A certificate issued by the U.S. Food and Drug Administration (FDA)

Service

The shaft seal of emulsification equipment, double-end set mechanical seal without dead angle, built-in mechanical pressure balancing system to cool and lubricate the mechanical seal, display pressure, up to 16 bar, entirely by the requirements of pharmaceutical specifications, surface treatment, the lowest exit without dead angle, these are the unique honor of IKA. DR series machine rotor line speed of 23m / s, three-stage high shear dispersion machine, mainly used for microemulsion and ultra-fine suspension emulsion production. Due to the three sets of dispersion heads (stator + rotor) working simultaneously in the working chamber, the emulsions are more delicate after high shear, with narrower particle size distribution, thus generating a more stable mixture, and all three sets of dispersion heads are easily replaceable for different process applications. The other models in the series have the same speed and shear rate, making it very easy to scale up production. Suitable temperature.

Applications: creams, cosmetics, toothpaste, fruit juices, salt solutions, catalysts, polymer emulsions, pesticides, herbicides, fungicides, etc.

Equipment series: mixer, blender, disperser, emulsifier, shear, homogenizer, grinder, colloid mill

Grinding equipment, homogenizing equipment, shearing equipment, emulsifying equipment, dispersing equipment, mixing equipment, stirring equipment, solid-liquid mixing equipment, powder-liquid mixing equipment, powder mixing machine, mixing and dispersing machine, dispersing emulsifying machine, emulsifying shearing machine, emulsifying homogenizer, shearing homogenizer, mixing and stirring, high shear emulsifying machine, high shear dispersing machine, high shear mixing equipment, high shear emulsifying and dispersing equipment, high shear emulsifying homogenizer Equipment

Series of equipment use form: online, batch type, pipeline type, pipeline type, continuous semi-continuous type

Series of equipment use range: laboratory pilot plant, large production

Colloid mill working principle

Working principle: Colloid mill is driven by an electric motor through the belt drive rotor teeth (or called rotor) and matching fixed teeth (or called stator) for relative high-speed rotation, one of the high-speed rotation, the other stationery, the processed material through its weight or external pressure (can be generated by the pump) pressurized downward spiral impact, through the gap between the fixed and rotor teeth (gap adjustable) when subjected to solid shear force The material is effectively emulsified, dispersed, homogenized and crushed by the physical effects of friction, high-frequency vibration, high-speed vortex, etc. to achieve the effect of ultra-fine powder and emulsification of materials.

Advantages of Colloid Mill

Compared with the pressure homogenizer, the colloid mill is first all a kind of centrifugal equipment, which has the advantages of simple structure, easy maintenance of equipment, and is suitable for higher viscosity materials and larger particles of materials. Its design also determines its main disadvantages. First, the flow rate is not constant because of the centrifugal motion, and the flow rate varies significantly for different viscous materials. For example, with the same equipment, in the treatment of dense lacquer materials and thin emulsion fluid, the flow rate can be more than ten times the difference; secondly, due to high-speed friction between the rotating stator and the material, it is easy to generate more excellent heat, so that the material being treated denaturation; third, the surface is more likely to wear, and after wear, the refining effect will be significantly reduced.

Application range

1, the food industry: aloe vera, pineapple, sesame, fruit tea, ice cream, moon cake filling, cream, jam, juice, soybean, soybean paste, bean paste, peanut milk, protein milk, soy milk, dairy products, whey cream, flavor, a variety of beverages, etc.

2, chemical industry: paints, pigments, dyes, coatings, lubricants, grease, diesel, petroleum catalysts, emulsified asphalt, adhesives, detergents, plastics, glass fiber reinforced plastic, leather, emulsification, etc.

、Daily-use chemical industry: toothpaste, detergent, shampoo, shoe polish, old cosmetics, bath essence, soap, balsam, etc.

Four 、Pharmaceutical industry: various syrups, nutritional solutions, Chinese patent medicines, cream pharmaceuticals, biological products, cod liver oil, pollen, royal jelly, vaccines, various ointments, various oral solutions, injections, static drip solution, etc.

Five 、Construction industry: various paints. Including interior and exterior wall coatings, anti-corrosion and waterproof coatings, cold porcelain coatings, colorful coatings, ceramic glazes, etc.

Six 、Other industries: plastic industry, textile industry, paper industry, coal flotation agent, nano-materials, and other industries for the production of high quality and environmental protection needs.

Structural advantages

One 、Internal tooth structure, small volume, low energy consumption; colloid mill motor is only 55KW.

Two 、Imported stator and rotor core components, unique anti-corrosion and anti-wear materials, to ensure a life of 200,000 tons or more.

three 、Colloid mill motors, the current impact is small, and the speed can be adjusted according to the requirements.

Four 、Colloid mill gap can be adjusted within 0.1~5mm.

Five 、Can make up to 20% of the polymer asphalt once through the grinding success, SBS minimum particle size up to 0.1μm, shear grinding capacity is ten times the ordinary colloid mill, significantly reducing the asphalt in the high-temperature state of the residence time, to prevent high-temperature aging.

Six, can shear grinding SBS, SBR, EVA, PE, waste rubber powder, rock asphalt, and other modified asphalt varieties.

Technical advantages

One 、Only the valve switch, the pump, and the mill run continuously, realize uninterrupted production.

Tow、can be customized according to user needs, all models are reserved for external interfaces, and can be extended its function and output, both fixed plant production and mobile on-site production.

Three 、There are two control modes: manual/automatic and manual.

Four 、Can produce super high modified emulsified asphalt (SBS content ≥ 4%, asphalt content ≥ 65%).

Five 、Can produce ultra-high content of modified asphalt (SBS content ≥ 12%).

Six 、On-site guidance on installation and operation, providing the most optimized and advanced production process and formula.

Installation and maintenance

Installation and operation steps

1、the equipment is installed horizontally on a flat concrete foundation and fixed with foundation screws (according to the working conditions can also be fixed).

2、check whether the fastening screws are tightened (the rotor center screw is an M12 left-hand screw).

3、before use, rotate the rotor with a particular trigger, check whether the contact with the stator, there is no jamming phenomenon, such as the situation mentioned above is not allowed to start the machine.

4、check and connect the power line (three-phase alternating current, voltage of 380 volts, body protection grounding) and note that the rotor rotation direction should be consistent with the arrow pointing on the base (clockwise rotation).

5、connect the cooling water and pay attention to the water nozzle in and out of the water sign.

6, when starting the motor, first tap the switch, and check whether there is noise or vibration. If the situation is not normal, should immediately stop, troubleshoot, and then test run.

7、 after work to clean the stator, residual rotor material should be in the running state, the first big chuck to counterclockwise rotation of not less than 90 ° after cleaning.

8、stator and rotor clearance adjustment method (adjustment should be carried out in the running state).

A: loosen the two handles b, move the handle to drive the big chuck rotation, gap adjustment, positioning disk clockwise rotation gap reduction, the material particle size becomes fine. The counterclockwise rotation gap increases and the material particle size is coarse.

B: fixed, rotor gap adjustment should be tightened simultaneously on two handles (clockwise).

C: according to the size of the processed material and batch requirements, choose the best-fixed rotor clearance that can be adjusted after the limit screw to limit the purpose.

9、 grease cups should be regularly filled with oil.

10、the requirements of the processing materials.

A: Can not process dry solid materials, only wet processing.

B: Materials should be cleared of debris before grinding, material size less than 1㎜, material hardness should not be higher than HV309, iron and gravel particles and other hard materials are strictly prohibited from entering the grinding head to prevent damage to the machine.

11、According to the material processing requirements, grinding can be done once or several times, and several experiments should be done before grinding to ensure the best gap and flow.

12、Before use, pay attention to the working condition of grinding and running time frequently. If there is any abnormal condition, it should be stopped immediately and disassembled for inspection.

13、Disassembly of stator assembly (please note that stator assembly one, two, and three should never be disassembled). First, remove the hopper to remove the inlet and outlet nozzle, loosen the cover screw, remove the dial, hold the handle, rotate counterclockwise to remove the large chuck, and lift the grinding head cover to remove the stator assembly.

14、The rotor assembly disassembly (please note that the rotor assembly one, two-rotor absolutely can not be decomposed). After putting forward the stator, remove the discharge port to unscrew the left screw will be able to remove the rotor and impeller. The rotor and stator assembly can be carried out in the reverse order as above, and each part should be cleaned before assembly. When installing, applying lubricant that meets the requirements on each contact surface and threads part after assembling is necessary.

15、colloid mill after use or not used for a short period should be well cleaned inside the cavity to prevent corrosion, preferably with high-pressure air blowing dry. Washing according to the different materials to choose the appropriate cleaning agent, but should ensure no damage to the seal (seal material with nitrile rubber).

16、Disassembly and assembly should pay attention to the seals should not be damaged, disassembled, or lost.

17、according to the required number of revolutions to replace the pulley, first loosen the motor cover end nut along the horizontal direction, push the motor towards the grinding head so that the v-belt relaxed, put the machine down, then unscrew the nut on the spindle and the motor shaft on the solid screw, remove the original pulley. When replacing the required pulley, use a hand hammer to knock in gently, do not hit hard so as not to damage the pulley and destroy the precision of the machine. After the replacement, tighten with nuts and screws and gently stand the engine up. After erecting the machine, push the motor in the horizontal direction to pull the v-belt and then put it on the cover.

Installation and use

1、Connect the feed hopper or feed pipe and discharge port, then connect the discharge circulation pipe, then click the cooling water (JM-L50a,b without cold water pipe system) and drainage pipe.

2、install the power start device (if the conditions of the user can be equipped with an ammeter and indicator or frequency converter, etc.). After connecting the power supply, pay special attention to the direction of operation to determine whether the average direction of rotation of the motor or from the feed pipe diameter to see whether the guide of the same as the 'red warning signs on the colloid mill rotational direction arrow consistent with the turn. Prohibit idling (cavity lack of material liquid) and reverse rotation.

3、in the factory, the equipment out of the square has been equipped with adjustable limit screws, grinding disk gap in the best processing fineness spacing. To adjust the grinding disk gap, first, the upper limit screw on the square of the material outlet is loosened, without turning on the machine, the two handles on the regulating disk (dial) 'counterclockwise' loosen, and then 'clockwise' turn the regulating disk, when turning the regulating disk feel a slight resistance to stop immediately At this time, the reading of the pointer on the scale aligning body on the regulating disc determines the dynamic and static grinding disc gap as '0'. But the reading number on the dial circle should be remembered; this number is not 0 degrees and between the grinding disc for '0', and then reverse (counterclockwise) a few turns to adjust the disc so that the gap between the moving and static grinding disc is slightly greater than 0. The scale of the adjustment disc is 0.01mm for each advance and retreat of a large frame. Generally, in the case of meeting the requirements of the fineness of processed materials, as far as possible to maintain a particular spacing between the grinding disk gap, while the handle will adjust the disk lock, and then the inlet square upper limit screws to ensure the regular operation of the machine.

4 、After connecting the cooling water, inject about 1~2Kg of liquid or other liquid related to the processed material and keep the wet cloth in reflux through the circulation tube. Then you can start the colloid mill after regular operation immediately into the colloid mill processing production, and idle type colloid mill can also be free of this.

5 、Before shutting down the machine, the feed hopper is added, the cavity is left with an appropriate amount of water or other liquids related to the processed materials, and the wet material is kept in a state of reflux through the circulation tube. Turn on the machine to maintain a certain amount of damp cloth in the hopper can be refluxed and immediately into the material; otherwise, it will damage the complex combination of seals or even cause leakage and burn the motor.

6、processing materials to pay attention to the motor load, found overload to reduce feeding.

7、colloid mill in action, never close the discharge valve to avoid excessive pressure in the mill cavity and cause leakage.

8、colloid mill is high-precision machinery, grinding disk clearance is very small, fast-moving. Operators should strictly adhere to their posts according to the rules and regulations of the operation, find fault in a timely shutdown, and troubleshoot before production.

9、colloid mill after use, should be thoroughly disinfected, clean the inside of the body, and do not make the material residue in the body, so as not too hard mechanical bonding and damage to the machine.

Special attention

Processing materials are never allowed to be mixed with quartz sand, broken glass, metal chips, and other complex substances, strictly prohibited from entering the colloid mill production.

Start, shut down and start cleaning before and after the colloid mill body must be left with water or liquid materials; prohibit idling and reversal. Otherwise, improper operation will seriously damage the complex mechanical components, static grinding discs, or dynamic grinding discs, leak and burn the motor, and other failures.

The product will be improved without notice when it does not affect the basic structure and performance.

Maintenance and Care

(1) Check whether there is any loosening of the colloid mill pipeline and the bonding place. Rotate the colloid mill by hand and see if it is flexible.

(2) Add bearing lubrication oil to the bearing body, observe the oil level should be at the center line of the oil mark, and the lubricant should be replaced or replenished in time.

(3) unscrew the pump body of the colloid mill water screw plug and fill the water (or slurry).

(4) Close the gate valve of the outlet pipe and export pressure gauge, and import vacuum gauge.

(5) Ignite the motor and see if the motor steering is correct.

(6) Start the motor, and when the colloid mill is running normally, open the outlet pressure gauge and the inlet vacuum pump to see if they show the proper pressure, then gradually extend the gate valve and check the motor load at the same time.

(7) Try to control the flow and head of the colloid mill within the range indicated on the label to ensure that the colloid mill is in the highest efficiency point of operation to obtain the maximum energy-saving effect.

(8) During the operation of the colloid mill, the bearing temperature should not exceed the ambient temperature of 35C, and the maximum temperature should not exceed 80C.

(9) If the colloid mill is found to have abnormal sound should immediately stop to check the cause.

(10) When the colloid mill is to be stopped, close the gate valve and pressure gauge and then stop the motor.

(11) Colloid mill in the first month of work, after 100 hours to replace the lubricant, after every 500 hours, change the oil once.

(12) Adjust the packing gland frequently to ensure that the drip inside the packing chamber is expected (to become a drip leak out as appropriate).

(13) regularly check the wear of the sleeve; wear larger should be replaced promptly.

(14) colloid mill in the winter season, the pump body needs to unscrew the lower water release screw to release the media net after parking. Prevent freezing and cracking.

(15) colloid mill for a long time out of use, the pump should be completely disassembled, dry water, the rotating parts, and grease installed, adequately stored.

Development status

The current status of the colloid mill

Colloid mills are widely used in various fields of national life, and there are wide varieties of colloid mills because they need to adapt to the requirements of different working conditions. China's colloid mill manufacturing industry is vast, with thousands of colloid mill manufacturers all over the country. China has become one of the countries with the world's most significant production and market demand for colloid mills. But most of China's colloid mill industry are small and medium-sized enterprises, good and bad, with the annual output value of more than 100 million yuan less than 10, even compared with other domestic machinery industries, whether in terms of equipment or technical level there is a big gap, really can independently research and develop high-end products in very few units, and thus in ample nuclear power, petrochemical, oil and gas pipeline lines, and other significant projects, supporting the colloid mill Mainly rely on imports.

Colloid mill enterprises attach great importance to the development of new products. It can be seen that China's colloid mill industry has developed to today. However, there is still a gap with the advanced international level; it has gone beyond the stage of simply copying and absorbing. In the search for further development of technology, we should analyze and learn from advanced foreign products. At the same time, we should think and analyze the trend of colloid mill technology development and product development from a deeper level and strive to develop new products with independent intellectual property rights.

Development trend of colloid mill

The theoretical research of colloid mill dry technology can be summarized into three major parts: academic research of low-pressure space and low-temperature heat and mass transfer and study of thermal property parameters and their measurement methods. Among them, the theoretical analysis of low-pressure and low-temperature heat and mass transfer was carried out earlier, and the results are more prominent. The recognized models of the colloid mill can be summarized into three types.

(1) The steady-state model of uniform backward movement of the ice interface (URIF) was proposed by Sanda11 et al. in 1967.

(2) The quasi-steady-state model was proposed by Dryer et al. in 1968.

(3) the adsorption-sublimation model was proposed by Litchfield et al. in 1979.

These models can describe the colloid mill process, but they all have shortcomings, defining the heat transfer process more accurately and the mass transfer process with more significant errors. The main problem is that the phase change of the solid-vapor phase has to occur during the mass transfer process, and the water vapor is transferred in a porous channel, and the channel length has to change with time, which is a non-stationary process. The structural size of the permeable channel is also related to the pre-freezing speed and the material structure of the colloidal mill product. No breakthroughs have been seen in the research reports in recent years.

The theoretical focus of heat and mass transfer in the colloid mill process is on the processes occurring within the material being colloid milled. The academic study of the unsteady flow field focuses on the low-pressure, low-temperature spatial environment outside the material and within the colloid mill, which is described by parameters such as temperature, pressure, and humidity. The unsteady flow field in the condenser of the colloid mill adds another problem of vapor-solid phase change, which further complicates the study. Therefore, although some people have studied and published papers in recent years, none of them have formed a compelling theory, and it is still one of the topics worthy of in-depth study.

Model Selection

Colloid mill selection reference

It is advisable to use the circulating tube type for crushing thin materials, which can process the materials automatically and repeatedly and facilitate the connection between the upper and lower processes.

The straight outlet type with a scraper is suitable for crushing viscous materials.

High hard teeth are suitable for crushing hard materials. High problematic tooth colloid mill adopts a unique technology method; the hardness of grinding teeth can reach HV1400～1600.

The crushing processing of joint building paint and foundry paint can use a paint mill, the grinding seat of the paint mill is carbon steel material, and the price of the paint mill is low.

Factory inspection

A. Each colloid mill must be inspected and passed by the inspection department of the manufacturer, and a certificate of conformity is attached before leaving the factory.

Second, each colloid mill factory must be in the rated speed of 30min no-load test; the product should meet the following requirements.

1、 the machine usually runs smoothly, with no abnormal sound, and the manipulation device is flexible and reliable.

2 、The connection parts and fasteners shall not be loose.

3、 batch production of products, at least two units per year, should be randomly tested; according to the provisions of the JB/T9820.3 test, the results should be in line with the requirements.

4、 the ordering unit acceptance of products should be by this standard for approval. If it fails, it shall be re-submitted for acceptance by the manufacturer after repair.

In the use of units to comply with the manufacturer's instructions for the use of the mixer conditions, from the date of purchase within one year, due to poor manufacturing quality and damage, the manufacturer should be repaired, replaced, and returned.

5、the quality of the paint coating should be JB/T?5673 inspections by the provisions.

Three, signs, packaging, transportation, and storage

1, each colloid mill should be fixed in a conspicuous position product label, the label should be in line with the provisions, and the title should be marked as follows

(a) the manufacturer's name.

(b) product name and model.

(c) spindle speed.

(d) productivity.

(e) supporting power.

(f) machine weight.

(g) product manufacturing number.

(h) product factory date.

2 、The rotation direction of the rotor is marked with a red arrow at a prominent position in the housing.

3, the colloid mill should be a packaged factory; the packaging should be easy to transport and ensure that the product is not damaged.

4, the accessories (spare parts and tools) supplied with the product should be complete.

5, each product should be accompanied by the following documents.

a) Packing list.

(b) product quality inspection certificate.

(c) product manuals.

(d) user opinion questionnaire.

6, all the documents are sealed in plastic bags and fixed in the box.

Seven 、Colloid mills should be stored in moisture-proof and rain-proof facilities.

Colloid mill maintenance and repair

1, colloid mill for high-precision machinery, line speed up to 20m / s, and grinding disk clearance is minimal. After repair and installation, a percentage table coaxiality error of the shell and spindle ≤ 0.05mm must be corrected.

2, when repairing the machine, in the process of disassembly, installation and adjustment back, never use iron clock direct knocking. Should be a wooden hammer or pad on the wooden block, gently knocking so as not to damage the parts.

3, the machine seals: are divided into static and dynamic seals. Static seal using O-type rubber ring, dynamic seal using hard mechanical combination seal. Found hard seal surface scratches should be immediately in the flat glass or flat castings for grinding repair; grinding material for ≥ 200 # silicon carbide grinding paste is good. If the seal is broken or cracked seriously, please replace it immediately.

4, the process of use should be based on the processing of materials, as appropriate, for regular maintenance.

5,For the maintenance of the motor, please refer to the instruction manual.