The DZZK series single cone spiral belt vacuum dryer is an efficient and multifunctional fully enclosed vertical vacuum drying equipment that integrates drying, crushing, and powder mixing. Its drying efficiency is 3-5 times that of the same specification "double cone rotary vacuum dryer". Mainly used for powder drying in industries such as pharmaceuticals, chemicals, pesticides, and food, it can achieve continuous operation in a closed process and is the drying equipment for the above-mentioned industries.
The drying and mixing of powders is an important step in the production of active pharmaceutical ingredients, so the selection of drying and mixing equipment is the guarantee of the final product quality and the key to determining the production and operating costs. Our company's newly developed "DZLG series single cone spiral vacuum dryer" leads the drying technology in the domestic chemical and pharmaceutical industry with its unique structure and absolute advantages.
1、
The selection of dryers needs to meet the specific requirements and characteristics of various products and processes. The content mainly includes the following aspects:
A. Most of the raw materials processed in production are thermally sensitive, so material clumping often occurs during the drying process. This requires shortening the drying time as much as possible to improve drying efficiency.
B. In material production, the purity of the circulating gas used in the drying process can have a significant impact on the quality of the material. This device adopts a unique gas supply technology to minimize the impact of gas on the drying process. From the perspective of operational economy, it is hoped that all process pipelines can be fixedly installed to save the required rotary space for double cone dryers.
C. In order to ensure the continuity of the entire process and reduce material leakage losses, the solid discharge flow rate of the dryer is controllable. This can reduce the workload of manual loading and unloading in the cleaning area and prevent material from being washed out.
2、Structure and characteristics of single cone vacuum dryer：
A. The working process of the single cone vacuum dryer is an intermittent batch operation. After the wet material enters the silo, it is heated by the jacket on the cylinder wall and the inside of the propeller, so that the heating area reaches 140% of the entire container area, and the material is heated and dried. And select the corresponding cone type drying mixer model (working volume) to achieve the desired drying effect. The hybrid dryer with an upward drive structure has the characteristics of efficient drying and mixing capacity, ample space, and easier maintenance for users.
B. Smooth operation, protecting crystal form:
The single cone vacuum dryer does not use any auxiliary tools during the drying and mixing process, only utilizing the revolution and rotation of the conical stirring screw. This allows the material to be continuously sheared and dispersed by the lifting from the stirring screw, ensuring that all materials in the silo can move fully and that the material is not subjected to any external force except for the lifting from the spiral slurry. This avoids ineffective friction between the powder, equipment, and powder grains, which is often the main factor leading to the destruction of the material crystal shape. This is also the fundamental reason why LZG series spiral vacuum drying can maintain the integrity of material crystal shape during the operation process.
C. Top drive eliminates the possibility of contamination caused by shaft seals to the product:
By adopting top drive and relative bottom drive, this device can avoid the following drawbacks:
The mixing blade must be disassembled using specialized equipment for cleaning and maintenance;
It is difficult to achieve a truly pollution-free seal for the agitator shaft seal, and there is a lack of quality assurance.
D. Low operating energy consumption cost and high mixing efficiency:
The single cone vacuum dryer is driven by a motor and has a unique design. The screw driven by the motor is used to lift the material, without the energy consumption for discharging separately. It is worth noting that in the process of mixing and drying, traditional mixing and drying equipment provides a belt type stirring blade. Its working principle is that during the stirring motion, the moving material acts as a whole, and a large amount of energy is used for the circular motion of the entire material. Therefore, the drying efficiency provided by this stirring is low. The LZG series spiral vacuum drying provides a conical spiral stirring, where the entire stirring blade moves in a circular motion around the axis of the conical silo, ensuring that materials in different parts of the container are stirred. As the spiral stirring progresses, the material at the bottom of the silo is gradually lifted to the top of the container, and then naturally falls down, and so on. This mixing mode ensures that the materials inside the container are thoroughly and uniformly mixed, eliminating the possibility of material clumping during the drying process and greatly improving the mixing and drying efficiency of the materials. And it has the advantages of a wide range of processing capacity and low energy consumption per unit mass.
E. Easy to operate and maintain:
The mechanical structure of the single cone vacuum dryer is simple and effective, easy for operators to understand, and the simple button control makes the operation process very simple. Some maintenance work can be completed smoothly and quickly even without professional personnel, and the set manhole can easily adjust and maintain the moving screw without complex disassembly. The device has very few vulnerable parts, and the drive unit such as the bearing box is located at the top of the silo. Users can easily remove the entire unit during maintenance, and the space for the top drive unit is also relatively spacious.
1. The equipment adopts jacket and screw internal heating, which increases the overall heating area of the equipment by about 40%.
The single screw belt agitator used in the equipment is a patented product of our company, which can achieve the effect of bottom-up circulation stirring and obtain efficient forced heat transfer performance. When the material loading rate is between 40% and 100%, 100% heating utilization can be achieved. Suitable for mixing and drying delicate materials.
3. Fully sealed system, no foreign matter contamination, high cleanliness, especially suitable for mixing and drying of pharmaceutical intermediates and raw materials, as well as for mixing and drying sterile raw materials.
4. The small gap between the single screw mixer and the container wall can effectively prevent materials from sticking to the surface of the container wall.
5. Adopting a small angle conical cylinder structure, the unloading speed is fast, clean, and does not accumulate material.
6. Equipped with a recoil device:
The dust raised during the material drying process is adsorbed onto the vacuum trap, blocking the vacuum channel. The obstruction of the gas channel directly leads to an extension of the drying time. The lower the temperature and shorter the drying time of the material during the drying process, the less the impact on the quality of the material. In response to the above reasons, our company has developed a single cone dryer with a back blowing device installed on the vacuum collector, which can maintain the smoothness of the vacuum channel during the material drying process, thereby ensuring the drying time and quality.
7. The bottom discharge valve is a suction valve with reliable sealing, which is conducive to vacuum drying.
8. The equipment has a compact structure, operates smoothly, has good sealing, no lubrication leakage, is easy to operate, and has a long service life.
This machine is equipped with a heating jacket on the heating cone, and the heat source is hot water, thermal oil or low-pressure steam, so as to maintain a certain temperature on the inner wall of the cone. The variable frequency speed regulating motor drives the single screw belt agitator to rotate through a parallel helical gear reducer, and the animal material is rotated along the conical cylinder and lifted from bottom to top. After the material reaches the high point, it automatically flows towards the center of the vortex and returns to the bottom of the conical cylinder by gravity and inertia. The entire process forces the material to be heated inside the conical cylinder, with relative convection and mixing. The heat diffuses among the materials, causing them to undergo irregular reciprocating motion in all directions, completing high-frequency heat transfer and exchange between the material and the single screw belt and cylinder wall surface, and achieving the effect of heating and drying in a short time. Thus, the internal moisture of the material continuously evaporates. Under the action of the vacuum pump, the water vapor is drawn out by the vacuum pump. If it is necessary to recover the liquid, a condenser or a recovery liquid storage tank can be used for recovery. After drying, open the discharge valve at the bottom to discharge the material.
This machine consists of a motor, reducer, frame, mechanical seal, metal sintered mesh filter, hollow double screw belt agitator, conical cylinder with jacket heating, and discharge valve.
1. Transmission and sealing parts:
Composed of an electric motor, reducer, frame, and mechanical seal.
1.1 Electric motor: Adopting variable frequency speed regulation motor, the speed can be adjusted as needed during operation.
1.2 Reducer: The SLFA series helical gear reducer runs smoothly and reliably, with low noise and a long service life.
1.3 Rack: Self designed and manufactured with high precision. Equipped with two sets of roller bearings, the mixer height and radial swing can be adjusted.
1.4 Mechanical seal: Single end sanitary type with material receiving flushing chamber, good sealing performance.
2. Blender:
The hollow mixing shaft is connected to the hollow ribbon with support rods, and the upper and lower ends connected to the hollow ribbon are formed with hollow support rods to form a circuit that can pass through the heat medium. In order to ensure that the material does not adhere to the cylinder wall, the gap between the screw belt and the cylinder wall is very small.
3. Tank body:
This part consists of an upper head, a conical cylinder, a vacuum filter, a discharge valve, etc.
3.1 Upper head: carries the transmission part and agitator; The inner surface connecting ports have rounded transitions. All materials in contact with the material are 316L. The process pipe openings are as follows: DN400 sanitary manhole, pressure gauge, explosion-proof sight light, sight glass port, feeding port, cleaning port, vacuum port, etc.
3.2 Lower cone with heating jacket: The inner surface is smooth and free of dead corners, which can fully dry the material. When discharging, use the rotation of the mixer to quickly and cleanly discharge the material.
3.3 Filter: Metal sintered mesh is used, with high filtration accuracy and large filtration area. And an exhaust port is set up at the vacuum outlet to perform compressed air blowback regeneration on the filter during exhaust.
3.4 Discharge valve: Adopting a suction valve, its discharge speed is fast, operation is convenient, and there are no residues or dead corners in the discharge.
