1800KGS-2100KGS/Hour PE-LB023-250 Raw Wool Scouring Line, Raw Wool Washing Machine, Raw Wool Washing Equipment

1800KGS-2100KGS/Hour PE-LB023-250 Raw Wool Scouring Line, Raw Wool Washing Machine, Raw Wool Washing Equipment, Raw Wool Scouring Equipment, lana cruda lavadora,  raw wool pesumasin, raw lana washing machine, ruwe wol wasmachine, bulu mentah mesin basuh, wol wasmasjien

Capacity: 1800KGS-2100KGS Raw Wool/Hour

Model: PE-LB023-250

WhatsApp/Mobile: +86-13738082939, Skype: wikimachine, Tel.: +86-571-82136157

Equipment List assumed for this analysis

Bale Breaker

Double Drum Opener

Greasy Feeder

Weighbelt and Feed-in Conveyor

1 set Cold Wash Bowl 8m length

5sets Steam heated Bowls bowl length 8m, 6m, 4m, 4m, 6m

6sets Squeeze Presses

8 Drum Dryer  (1.8m dia drums)

Scoured Wool Opener Duster(4 Drum)

Wool grease Recovery Plant including 3 Centrifuges (client supply)

Wool Type

Fine Merino 15-20 micron

Wool Throughput

1800 - 2100kg/hr of greasy wool, depending upon wool micron and yield..

Scoured Wool Quality

Final Regain:Usually 10-12% to suit client

Residual Grease: 0.3 – 0.5% but can be easily varied to suit client’s needs

Ash Content on fiber 0.4 – 1% depending on greasy yield and rinse water usage

Services

Steam Consumption at start up: 3,000kg/hr

Steam Consumption while running: 1.0 – 1.2 kg/kg clean wool

Steam Pressure: 5.5 – 7.5 bar (80-110psi)

Water Consumption:10 – 45 litres/kg scoured wool depending on throughput, wool type and method of operation

Water Volume of Plant: 200 cu.m total

Compressed Air Consumption: 10 Standard cu.m/hr

Compressed Air Pressure:  7 bar (100 psi)    

Detergent Type: Nonionic neutral (e.g. ICI Terric GN9 or Shell

Detergent Consumption:  7-12kg/T greasy merino wool

Electricity Consumption: 220-260 kVA depending on wool load

Woolgrease Recovery: 40-55% of that on the greasy wool

Equipments List

1.72meter Bale Breaker

Description:

The Bale Breaker is the first unit of the LB023-250 scouring line. This equipment is designed to open the raw wool in the bale.

Technological process: raw wool is put into the hopper, which has the capacity of 3 tonnes, transported through the metal lattice to the bale breaking roller for opening. The volume of wool through the system is regulated by photoelectric control. The motors of bale breaking rolls are controlled by a frequency control device for variable speed.

Diameter and speed range:

 Top bale breaker roller

Diameter: φ900

Rotational speed: 163~81r/min

Linear speed: 460~230m/min

Middle bale breaker roller

Diameter: φ900

Rotational speed: 233~116r/min

Linear speed: 658~330m/min

Main bale breaker roller

Diameter: φ1000

Rotational speed: 120~60r/min

Linear speed: 377~188m/min

Inlet and outlet lattices:

1.  Inclined inlet lattice (metal lattice) φ200

                         Rotational speed: 3.6~1.8r/min

Linear speed: 2.26~1.13m/min

2.  Flat inlet lattice (metal lattice) φ200

                         Rotational speed: 2.2~1.1r/min

Linear speed: 1.38~0.60m/min

3.  Outlet lattice (rubber lattice) φ200

                         Rotational speed: 24.5~12.2r/min

Linear speed: 15.4~7.7m/min

Power source:

Top and middle bale breaker roller

GSA8T-Y7.5KW-4P 1:8.81; VFD for variable speed

Main bale breaker roller

GK97-18.5KW-4P 1:11.99; VFD for variable speed

Inclined Inlet lattice

14# base BWD1:87, 2.2KW-6; VFD for variable speed

Flat Inlet lattice

120# base BWD1:187, 0.75KW-4; VFD for variable speed

Outlet lattice

GSA67-Y1.1KW-4P 1:36.85; VFD for variable speed

Overall dimensions:

L×B×H=9710×2360×4100

Overall weight:

Approx. 12 tonnes

Power source:

30.05KW

2.5 meter Feed hopper

Description:

The Feed Hopper is supplied wool from the wool from the 5 meter long Greasy Wool In feed Conveyor for even feed of product into the Double Drum Opener.

It is manufactured from pressed 5mm steel plate.

A PVC horizontal conveyor and Aluminum Heavy Duty Spiked Lattice are each driven by a shaft mounted gearbox.  Both conveyors are driven by a single variable speed control.  The spiked lattice has polyethylene pinned slats bolted to the inside of the PVC mat, with the pins protruding through the PVC mat.  The lattice is driven by a large diameter rubber coated top drum.

The Comb and Doffer Drums are both driven with shaft mounted gearboxes and motors

Horizontal conveyor:

Power: 0.75KW-4P; VFD for variable speed

Rotational speed: 12r/min

Linear speed: 8.21m/min

Spiked lattice conveyor:

Power: 2.2KW-4P; VFD for variable speed

Rotational speed: 101r/min

Linear speed: 79.29m/min

Comb Drum:

Power: 1.5 KW-4P; VFD for variable speed

Rotational speed: 72.5r/min

Linear speed: 207.16m/min

Doffer Drum:

Power: 1.5 KW-4P; VFD for variable speed

Rotational speed: 144r/min

Linear speed: 312m/min

Overall dimensions:

L×B×H=4625×2350×3000

Overall weight:

Approx. 5 tonnes 

Power source:

5.95KW

Double Drum Opener

Description:

The wool is transferred from the Feed Hopper to the Double Drum Opener infeed belt and into the infeed nip rollers. When the wool enters the first and second drums dirt and other foreign matter is removed through the self-cleaning screens under the rotating drums. The dirt and other contaminants are removed from under the machine by a dirt conveyor located under the Opener. The wool is opened and prepared for washing. Contaminants are reduced in this process.

Specification and features:

Working width: 2500mm

Inlet roller:

Power: 1.5KW-4P×2; VFD for variable speed

Rotational speed n1: 25.47r/min

Rotational speed n2: 13r/min

Dirt conveyor:

Power: 0.75KWP4;

Rotational speed: 29r/min

Drums:

Power: 22 KW; VFD for variable speed

Drum One

Rotational speed: 403r/min

Drum Two

Rotational speed: 453.5r/min

Auto-Cleaning Screens

Hydraulic Pump Motor 2.2KW-4P

Type: automatic pull-out powered by hydraulic-cylinder

Screen Open Area: 10mm bar 12mm gaps  

Overall dimensions:

L×B×H=3970×4500×2600

Overall weight:

Approx. 6 tonnes

Power source:

32KW

2.5 meter Feed hopper

Description:

The Feed Hopper is supplied wool from the Double Drum Opener. It takes the wool out of the hopper for delivery in an even manner to the Weighbelt.

It is manufactured from pressed 5mm steel plate.

A PVC horizontal conveyor and PVC Spiked Lattice each driven by a shaft mounted gearbox.  Both conveyors are driven by a single variable speed control.  The spiked lattice has polyethylene pinned slats bolted to the inside of the PVC mat, with the pins protruding through the PVC mat.  The lattice is driven by a large diameter rubber coated top drum.

The Comb and Doffer Drums are both driven with shaft mounted gearboxes and motors

Horizontal conveyor:

Power: 0.75KW-4P; VFD for variable speed

Rotational speed: 12r/min

Linear speed: 8.21m/min

Spiked lattice conveyor:

Power: 2.2KW-4P; VFD for variable speed

Rotational speed: 101r/min

Linear speed: 79.29m/min

Comb Drum:

Power: 1.5 KW-4P; VFD for variable speed

Rotational speed: 72.5r/min

Linear speed: 207.16m/min

Doffer Drum:

Power: 1.5 KW-4P; VFD for variable speed

Rotational speed: 144r/min

Linear speed: 312m/min

Overall dimensions:

L×B×H=4625×2350×3000

Overall weight:

Approx. 5 tonnes

Power source

5.95 KW

2.5 meter Weighbelt

Description:

The Weighbelt is designed to provide a regulated feed of wool to the scour line controlled by a pressure transducer. The flowrate of the wool feed depends on the origin, micron range and desired production rate. The weighing conveyor is supplied complete with a fabricated mild steel frame designed to suit the application.  The conveyor has a PVC belt which is cantilevered from one end and supported by a load cell at the other end.  The load cell is hermetically sealed and fitted with overload protection and locking bolts for use in transit or maintenance.  The feedrate control system comprises a load transmitter and a software controller incorporated into the electrical package.

Specification and features:

Power source: 0.75KW-4P

Speed range of Conveyor (VFD)

Rotational speed n1: 13.1r/min

Linear speed v1: 6.42m/min

Rotational speed n2: 6.55r/min

Linear speed v2: 3.2m/min

Weighbelt controller EMC …

Overall dimensions:

L×B×H=1820×2520×1710

Overall weight:

Approx. 1 ton

Power source:

0.75KW

2.5 meter Infeed Conveyor

Description:

The infeed Conveyor is designed to transfer the evenly distributed wool from the Weighbelt into the first scouring bowl. The conveyor consists of a fabricated stainless steel frame and rollers. It has a PVC conveyor belt with B tracking strips for traction of the greasy wool and is driven by a shaft mounted geared motor.

Specification and features:

Power source: GSA67 1:56.89 M4 1.1KW-4P

Speed range of Creeper Lattice (VFD)

Rotational speed: 25.5r/min

Linear speed: 12m/min

Rotational speed: 12r/min

Linear speed: 5.65m/min

Overall dimensions:

L×B×H=2280×2500×2880

Overall weight:

Approx. 0.5 ton

Power source:

1.1KW 

2.5 Meter Scouring Bowls

Description:

The scouring machines are the main components of the scouring line. This equipment is designed to wash the wool after opening and dusting and prepare it for drying.

Scour Bowls – Steam Heated

2500mm working width

Bowl scour liquor heated by a steam heated exchanger located underneath the bowl in the flow round pipework

Bowl shells will be fabricated from 304 stainless steel.

Pneumatically operated knife type dump valves fitted to the bottom of each hopper, and supplied complete with 24 volt solenoid controls and all pneumatic fittings and piping.

Hopper bottomed squeeze tanks located beneath the main bowl collect the liquor squeezed from the wool by the squeeze press and are designed to act as the reservoir for the flow round circulation pump. Rotary perforated screen flock catchers are fitted to the side tanks to continually remove fibre from the circulating liquor, this fibre is automatically recycled back to the bowl by a pneumatic pump..

On Bowl one only has a perforated stainless steel flow through rotating immersion drum designed to thoroughly and quickly wet the incoming wool.  This unit is driven by a shaft mounted geared motor.

Bowl one is not heated and is designed as a suint bowl. It comes with larger diameter holes in the bowl screen.

Three rows of rakes (with a circular motion) in the body of the bowl and specially designed head rakes at the outlet of the bowl to deliver the wool to the squeeze press. The head rakes and the main rakes are driven by separate variable speed shaft mounted geared motors.

Perforated stainless steel bowl screens which allow the heavy solids to settle to the bottom of the bowl.  The screens are firmly supported and fixed to the bowl to ensure that lumps of wool cannot pass into the hoppers beneath, and they are strong enough to support staff walking on them for cleaning or maintenance purposes.

An overflow system which provides fine control for the level of the liquor in the bowls.

Elevated frames and walkways either side for the bowls and presses.  They require no special foundations and enable rapid erection of the plant in the client’s factory.  The framework also includes pipe racks on which all the necessary service pipework and valving within the assembly of the bowls and presses has been pre-assembled in the factory prior to shipping.

The piping and valving supplied includes:

Wool grease recovery plant draw off from the side tank of the first hot scouring bowl

Fresh water mains and bowl filling lines

Flow back (counter-flow) between bowls

Drainage

Flow round (bowl circulation)

Pneumatic pipework

  Steam and condensate mains

Compressed air

For maximum corrosion resistance all black steel work will be galvanised, or etch primed and painted where hot dip galvanising is impractical.

Integrated operator station panel providing the operators with all the finger tip controls for the bowls and associated presses.  The panels feature pictorial labels.

Electrically operated emergency lanyard runs the full length of the scour bowls on both the operator and service side walkway.

Parameters of the 6 washing bowls:

Suint Bowl 1: 4 hoppers with automatic drainage valves

Total length: 8m

First Scouring Bowl 2: 4 hoppers with automatic drainage valves

Total length: 8m

Second Scouring Bowl 3: 3 hoppers with automatic drainage valves

Total length: 6m

Third Scouring Bowl 4: 2 hoppers with automatic drainage valves

Total length: 4m

First Rinsing Bowl 5: 2 hoppers with automatic drainage valves

Total length: 4m

Second Rinsing Bowl 6: 3 hoppers with automatic drainage valves

Total length: 6m

Main rake motor: 1.5KW-4P×6=9KW

Main rake rotational speed: n1=17r/min, n2=10r/min

Head rake motor: 1.5KW-4P×6=9KW

Head rake rotational speed: n1=39.35r/min,n2=23r/min

Pressing roller rotational speed: n1=6r/min,n2=3.53r/min

Parameters of the Side Tank:

Quantity: 6

Two small hoppers with automatic drainage valves

Capacity: 3.3 M³ X 6 =19.8 M³

Bowl 2 side tank has additional baffles to allow wool grease take off.

Flow round pumps

Circulation pumps provide high scour liquor circulation from the side tanks via the heat exchanger to the bowl.  Each pump has ample capacity to operate a controlled flow back system to the preceding bowl.  The pumps are designed specifically for the application and are glandless with stainless steel shafts/impellors and housings.

       Each pump has a 4Kw Motor

Circulation pump: G35-100

Flow rate: 100 M³/h

Head: 10m

Power: 4 KW X 6 = 24 KW

Total motor power for washing section: 42 KW

2.5Meter Squeeze Press 

Description:

The Squeeze Presses are components of the 2500ww scouring line. This     equipment is designed to provide variable squeeze pressures, and ensure minimal  carry-over of liquor between bowls and improved drying performance.

Squeeze Press (25 tonne bellows)

Six 2500mm working width squeeze presses to follow the bowls with the following features

The squeeze pressure is applied by two (2) pneumatic bellows mounted on each side above the bottom roller, and giving an adjustable total force of up to 25 tonnes.

The top roller is automatically lifted by two other smaller bellows which are activated when the air is vented from the pressurising bellows.

The rollers run in heavy duty spherical roller sleeved bearings

The bottom roller is manufactured from 304 stainless steel and for bowls 1, 2 and 3 the roller is grooved axially to positively grip slippery wool.

The top roller is nickel-chrome plated to resist corrosion and is lapped with nylon rope to provide optimum moisture expression from the woolmat.

The bottom roller is driven by a shaft mounted geared motor.  The top roller is connected to the bottom roller by a one-way clutch which drives the top roller if the top roller slips or stalls.  For bowls 1 and 6 and the roller speed is adjustable and controlled by separate variable speed drives.

The outfeed conveyor has a sectional conveyor belt which is self tracking.  This conveyor is driven by a chain drive from the press drive.

For maximum corrosion resistance all black steel work will be galvanised, or etch primed and painted where hot dip galvanising is impractical.

Guarding to protect operators from all moving components.

Specification and features:

Pressure generation. Pneumatic system with double pneumatic air springs

Squeeze pressure: 12-25 tonnes

Squeeze rollers diameter:

Top squeeze roller: φ430mm (φ350mm metal roller covered by 50*50 nylon rope)

Bottom squeeze roller: φ350mm.

Power source: 4KW*960r/min; VFDx6=24KW

Speed range of squeeze roller:

Rotational speed n1: 3.76r/min

Linear speed v2: 4.74m/min

Overall dimensions (6 Scour bowls + 6 Squeeze Presses+ ladders):

L×B×H = 50m × 4.5m × 3.5m

Machine weight:

Scouring Machines + Squeeze Presses = 9 tonnes each X6 = 54 tonnes

Total Power source:

24KW

Heavy Solids Loops 1 and 2

Two (2) heavy solids loops, designed to remove the heavy solids from the bottom of bowl 1 (Heavy Solids Loop 1) and bowls 2 and 3 (Heavy Solids Loop 2) and to recycle the clarified liquor to the wool grease plant.  The equipment for each circulation loop comprises:

Heavy solids pump – A centrifugal pump capable of handling entrained solids and driven by an electric motor.  In a closed flow system it pumps the scour liquor from the bottom of the bowl to the fibre strainer, then on to the hydrocyclone and finally back to bowl.

(b)   Fibre strainer – An in-line self cleaning rotary fibre strainer for removing fibre from the liquor flow.  Includes scraper drive motor and a 65mm NB knife valve discharge.

(c)   Hydrocyclones – Two (2) hydrocyclones for removing heavy solids from bowl 1 liquor.  The clarified flow is returned to the bowl and the underflow is drained to the underflow collection tank.

(d)   Flowmeter – A flowmeter for monitoring the feedrate to the hydrocyclone.  The flowmeter has digital indication of flow up to a maximum flow of 12,000l/hr 

2.5 meter Eight Drum Dryer 

Description:

The Drum Dryer for drying wool after scouring or for dyeing. Interval drying pattern improves overall efficiency due to high evaporation rate. 

Operation process:

Perforated drum dryer is a highly effective dryer. The inlet conveyor feeds the wool to the surface of the drum. The fan draws air from the interior of the drum producing suction on the surface of the area in contact with the material. This suction holds the wool to the surface of the drum permitting air to pass through the material being dried. After wet wool is applied onto the drum surface in a thin layer, heat transfer takes place due to a great temperature difference between the drum surface and the wet product.

A portion of the drum, the non-working surface, is sealed with a baffle and has no suction and permits the material to transfer to the next drum without interference. Uniform drying is achieved after several alternative dryings on both sides. Afterwards, the wool is transferred to the stepped opener duster.

Overall specifications:

Drums divided into 4 drying zones to provide air flow reversals and ensure    thorough drying of the entire wool mat.

Drums clad in 304 stainless steel to provide maximum corrosion resistance and durability.

Torque limit protection on drums from direct drive motor attachments

Pressure equalising decks above and below the drums to ensure even distribution of air flow within the drying chambers.

Individual shaft mounted variable speed, geared motor drives for drums.

Modular construction, fabricated in mild steel zinc coated panels, etch primed and painted. All panelling contains industrial duty insulation of 50mm thickness and a  density of 36kg/m³.

Fans of 9 bladed construction for increased circulation mounted as a plug design to facilitate easy removal and access for maintenance.

Exhaust with outlet damper to control air flow, humidity and air pressures within the dryer to provide a counter current airflow.

Steam distribution pipework, manifold, solenoid control valves and pressure switches

Working width: 2500mm

Capacity: 1500- 2000 kg/h (scoured wool)

Drum Drives:

Power source 0.5KW x 8 = 4KW

Fans:

Power source 30KW X 8 = 240KW

Infeed conveyor

Power source 0.75KW x 1 = 0.75KW

Rotational speed: 1.88r/min

Steam pressure: 0.4~0.6Mpa

Temperature: wool 85~95℃;

Moisture regain: about 10%

Overall dimensions: L×B×H=16.5m×3.9m×4.1m

Overall weight: 50 tonnes

Power source: 249KW

Specifications of key components:

Drums

Diameter: 1800mm

Working width: 2500mm

Material: δ=2mm, 304 stainless steel

Drum seal: high-heat-resistant silicone rubber board δ=3mm

Drum bearing: four fluorocarbon high-heat-resistant and oilless bearing, configured with the temperature control, auto alarm and auto emergency stop devices

Quantity: 8

Fans

Type: centrifugal Plug fan

Impeller diameter: 1150mm

Impeller outlet width:  610mm

Rotational speed: 1150 r/min

Air flow: 32000 m³/h

Total pressure: approx. 150 mm water column

Drive: belt drive

Motor: Y160-4-30KW three-phase asynchronous motor;

60s interval; automatic start

Heating

Type: pipe assembly; no wrapping steel strip;easy cleaning and maintenance

Material: φ48×3.5 seamless steel pipe

Quantity: 8 sets; 64 per set

Automatic temperature control with digital display

Inlet conveyor: PVC belt lattice, LXW 3454X2610mm

Outlet Shute: 2mm; 304 stainless steel

Exhaust: air exhaust between the first and third chamber; 600×600mm

Frame: Folded steel, channel & 100×50 rectangular box section

Insulation door:=2mm galve plate with a thickness of 50mm, sealed by high heat resistant silicone rubber seal

Lighting: 4 TM395 illuminators

2.5Meter 4 Drum Stepped Opener Duster

Description:

The clean wool is opened and dusted through this machine after it is dried through drum opener in preparation for further processing. The Stepped Opener ensures the clean wool has no felting to produce a better top length after carding and has less dust and foreign matter.

Operation Process:

After the wool exits the dryer it is fed onto the in-feed conveyor of the stepped Opener and into the machine through the nip rollers. The wool is then opened and dusted as it passes under the rotating drums and over the perforated screens.

The waste removed is pneumatically conveyed to dust bags.

Specification and features:

Short feed-in conveyor and nip roller to control the wool flow into the opener/dusting drums.

Easy access above and below the drums for cleaning and maintenance.

The drums are fabricated from mild steel and fitted with conical -shaped teet.

Beneath each drum is a screen constructed from perforated sheet steel.

The dust coming through the screens falls into a common collection chamber which are suitable for connection to the pneumatic dust extraction system.

Motor of in-feed flat lattice roller: 2.2 KW, VFD for variable speed

In-feed flat lattice speed Rotational speed n1: 13r/min

Power source of opening roller: 15 KW

Drum Speed: Rotational speed n1: 454r/min

Overall weight: Approx. 5 T

Overall dimensions: L×B×H = 4330×3220×2850

Power source: 17.2KW

WOOL SCOUR ELECTRICAL MANAGEMENT SYSTEM

Quality and consistency are important factors in any production process.  To meet these essential requirements the scourline has a computerised woolscour monitoring system.

General Description

The system consists of one or more programmable logic controllers (PLC’s) linked together to monitor and control woolscouring plant activity.  The PLC’s are connected to a personal computer that runs process software and displays plant information stored in the PLC’s.  Hard copies of the screens, reports, recipes and trends can be printed out on a printer attached to the system.

As the system is engineered to fit the individual customer requirements there is no exact specification for a system.  However a general specification is given in the following sections.

General Specification

Main Control Panels

These consist of three free-standing dual sided mild steel cabinets designed for mounting in a clean, dry, cool area.  One panel, the main MCC, houses the scour bowl electrical control equipment and the other panels house the greasy and dryer equipment.

The panels are designed and built to international standards.  They contain all the necessary equipment such as motor starters, variable speed drives, overloads and PLC equipment required for plant operation.

Plant Mounted Operator Stations

Operator stations are located near each key plant item.  Operator stations are supplied for each greasy hopper, the greasy opener, one per bowl, one for the dryer and one for post dryer equipment.  Each operator station contains illuminated pushbuttons for the local start and stop (or pause) for controlling the scouring plant machinery. 

Supervisory and Control System

The supervisory control system is based on a high end IBM compatible work station running the Windows™ operating system.  This computer is networked to the plant control PLC located in the main MCC.  The computer is configured with good graphics of all the plant equipment. The system has an intuitive operator interface designed to easily allow the wool scour plant operators and managers access to all the key plant information and controls

The computer is configured with user level security to prevent unauthorised access to controls and key operating parameters.  For example an operator will have access to only the main scouring variables while a technician will have full access to all critical plant tuning parameters.