coal vibratory feeder

Types of Coal Vibratory Feeders

A coal feeder is an instrument that regulates and controls the flow of coal to different equipment and parts. It plays a significant role in ensuring that a uniform supply of coal is provided to boilers, furnaces, and other areas that require coal as a primary fuel or raw material. Coal vibratory feeders, which are often used to supply small and consistent amounts of coal to particular areas, are a component of these coal feeders.

Aside from the coal vibratory feeder, there are, however, several other types of coal feeders:

• Rotary Disc Feeder

  This type of feeder operates by rotating plates that have been designed to supply raw material to the required area. It's commonly used to provide coal to air separation boilers and holds the function of helping with the uniform distribution of materials. The disc feeder can be used for various types of small granulated coal.

• Chain Drag Feeder

  In simple terms, a chain drag feeder operates by chains that drag the coal down to the area where it's required. This type of feeder is used in places where there are larger quantities of coal that need to be supplied in order to meet the demands of different processes and equipment that require coal as a primary raw material.

• Pan Feeder

  A pan feeder is preparatorily used to feed raw material to crushing and grinding equipment. It works by the help of a number of trays that vibrate in order to produce a consistent supply of coal that is small and manageable. This allows the raw material to be uniform in size, which helps with further processing.

• Colloidal Feeder

  Colloidal feeders are small devices that are used to assist in the supply of raw material to mixing tanks, hoppers, and other equipment that require coal dust, granules, or powder coal to function properly.

• Flexible Feeder

  This type of coal feeder is called the flexible feeder because it has the ability to supply coal to different areas by means of the equipment's ability to bend and adjust according to the requirements of the facility. It is popularly regarded as one of the most versatile feeders.

• Gated Feeders

  These types of feeders are used to regulate the flow of coal to different equipment and parts. The gate operates electrically, by gravity, or mechanically.

• Counter-Weighted Feeder

  A counter-weighted feeder is a type of feeder that operates on the basis of counterbalancing weights to stabilize and/or control the rate at which coal is supplied.

Specifications and Maintenance

Specifications

These are some specifications business buyers should know about coal feeders:

• Feed Rate:

  The coal feeder serves as the primary point of control for the mass flow rate of coal into the powder burner. Thus, it is built to have the capacity to deliver the initial coal amount that will secure stable combustion. Also, it is constructed so that it can be adjusted and calibrated precisely to allow the introduction of coal ranges that will provide the full operating range of the burner.

• Mass Flow:

  Mass flow is the actual coal amount fed to the burner per unit of time measured in kilograms per second. The coal feeder design must be able to allow a higher mass flow feeder of coal than the coal gravimetric feeder in order to accommodate the higher feed rates required by specific fuels, such as lignite.

• Drive System:

  The drive system is the mechanism that encourages movement and, eventually, the feeding of coal. It is necessary that the drive system has adequate torque and power so that it can carry the needed mass flow rates. In addition, the speed of the system must be manageable so that it can be calibrated, allowing the gravimetric calibration system desired.

• Hopper Volume:

  The hopper is the vessel in which raw materials are stored before the vibrational mechanism is launched, and coal feeding occurs. It is necessary that a suitable volume is available so that enough storage can be maintained until a sufficient rate of coal can be released to meet the burner's needs.

• Information Technology:

  For the accurate coal feeding and sustained proper functioning of the entire coal combustion system, open communication technology must be used. It must be possible for weight, velocity, and feeder position data to be exchanged over a standardized Ethernet communication system connected to a central data processing controller. This type of system will allow the feeder to be part of an integrated and spherical coal combustion control technology that has a sophisticated and standardized computer-based technology for entire system management.

Maintenance

Like any other appliances and machines, coal feeders require regular maintenance. Small mechanical speed reducers would need oil lubrication every three months, while large ones may require it bi-annually. All vibratory feeders should be greased every eight months, while for large ones, every 12 months would be enough. For roller bearings, the same routines apply. In addition to greasing the bearings and joints, lubricating the chain drives would be necessary every 12 months.

Coal feeder maintenance staff should examine the health of the chains and look for any possible stretch or crack. A quick check of the slack and tension would do, or they could refer to the manual for additional information. Spare chain links should be identified, purchased, and ready, along with the required tools for any chain issues.

Any obstructions that may harm the functioning of the coal feeder should be addressed, especially around the tracks where debris is most likely to gather. In the case of bigger impurities, a mini-magnet can be installed to pick up such debris before it gets into the coal mill and masses of coal.

While the feeder is functioning, operative staff should pay attention to its sounds. Any irregular thumps or squeals should be focused upon, and abnormalities should be treated right away. Fault diagnostics can be helpful during such times.

Clean the belt of any coal residue from time to time to avoid possible belt damage. It would help lubricate the belts with the required belt dressing system to avoid damage. Always consult the coal feeder system manual before attempting any repairs or damage.

Applications of Coal Vibratory Feeders

Coal feeders are mainly used in power plants and coal-based industries to ensure a steady and uniform supply of raw coal to the boilers/gasifiers. However, they are also used in several other industries and applications, which may benefit from a consistent supply of raw coal or other materials.

• Cement Industry: In the cement industry, vibratory feeders are used to supply raw materials like limestone, clay, and gypsum to different processing units, such as the crusher, dryer, and blending units.
• Glass Industry: Glass manufacturing units also use vibratory feeders to provide materials to furnaces. The feeders are responsible for ensuring uniformity and precision. Coal is commonly used as a reducing agent in some glass production processes to minimize the formation of certain undesirable compounds.
• Steel Industry: Vibratory feeders are pivotal in meeting the demands of steel manufacturing units, such as sinter plants, blast furnaces, and steelmaking converters. In these facilities, raw materials like iron ore, coke, and fluxes are processed to produce molten steel. These units have specific requirements for the supply of raw materials. For instance, feeders may be responsible for introducing a precise quantity of iron ore into a processing unit or blending several raw materials according to a predetermined formula.
• Aluminum Industry: Aluminum metallurgy involves several intricate procedures that require a variety of raw materials. In this context, vibratory feeders are used to supply materials such as alumina, carbon, and fluxes to different processing units like reduction cells and melting furnaces.
• Foundries: Foundries utilize vibratory feeders to achieve the necessary consistency and homogeneity of raw materials like ferroalloys, pig iron, and carbon additives.
• Food Processing Industry: Food processing operations, including grain processing, baking, and snack food production, employ vibratory feeders to handle and deliver raw materials like flour, sugar, and spices. The precise quantity and steady supply of these materials are essential for maintaining product consistency and quality.
• Pharmaceutical Industry: In the pharmaceutical industry, vibratory feeders are vital in handling and delivering raw materials like active pharmaceutical ingredients (APIs), excipients, and additives. These delicate components are crucial for formulating medications and ensuring product effectiveness and safety.
• Aggregate Industry: Aggregate production operations, such as those involved in the manufacturing of asphalt, concrete, and artificial sand, utilize vibratory feeders to supply raw materials including coal, cement, fly ash, carbon, and slags. These feeders ensure that the appropriate quantities and blends of materials are accurately and consistently delivered to the production processes.

Overall, coal feeders play a crucial role in improving the efficacy and quality of products in several industries by ensuring a constant supply of raw materials. They minimize wastage and losses by streamlining processes. Their consistent supply reduces the need for manual feeding and decreases feeding time, increasing overall productivity. Coal vibratory feeders increase operational efficiency by maintaining a constant flow and ensuring smooth transitions between units.

How to choose coal vibratory feeders

Before selecting a feeder for use in a plant or facility, it is important to first ascertain its application. Asking questions like where the feeder will be used, what type of material it will handle, and what parameters are significant to the process can help users find the model that best suits their needs.

Based on the answers to the questions above, users can determine the type of feeder to select. For instance, users who will supply materials in small sizes or who will support them in overcoming resistances will opt for electromagnetic feeders. However, users supporting large resistances and throughputs will choose an electromechanical feeder with a trough design that suits the material-carrying needs.

Users must assess the characteristics of the material that the vibratory feeder will transport. Factors such as humidity, temperature, particle shape and size, density, chemical composition, and the presence of any lumps must be considered. For instance, when carrying out sticky or wet materials, one may need to install additional devices such as scraping plates or vibrating rods to avoid clogging and ensure a stable flow.

A vibratory feeder's parameters include flow rate and feed size. The flow rate indicates the volume or weight of the goods passing through a section in a given time. In contrasting the installation of vibratory feeders with others, the feeder is typically installed closer to the processing equipment as a means of minimizing transportation costs and distances. Thus, the feeder should have a high flow rate.

When selecting the vibratory feeder, the conveying height and distance should also be specified. The feeder does not have to be the only component that supports the process. Other items with shorter or longer distances may be.

Vibration frequency and amplitude can be chosen when selecting a vibratory feeder for fine material, as different particles react differently to vibration. Besides, when selecting the feeder for use in a particular industry or application, the visitor should be concerned about the specific technical parameters of the chosen model, such as its energy consumption.

When installing the feeder for use in a particular industry or application, the user should worry about the specific technical parameters of the chosen model, such as its energy consumption. Dust in the environment may also be a factor of concern, as the feeder will expose processing equipment or personnel to harmful substances that need to be contained.

Finally, support availability is essential when choosing a vibratory feeder. Unlike feeders with fixed speeds, vibratory feeders have motor speeds that need to be supported by manufacturers. Enterprises looking to purchase a coal feeder in bulk should ensure they get a quality product that meets the requirements of their coal handling systems and the manufacturer's support service.

Coal vibratory feeder FAQ

Q1 What is the difference between a feeder and a feederbreaker?

A feeder is a device that can be used to evenly deliver material at a desired rate, thereby providing a stable supply of material. A feeder-breaker, however, is a typical underground mining machine used to break coal and rock.P

Q2 Are vibratory feeders energy-efficient?

A vibratory feeder is an energy-efficient device. Its design optimizes the usage of electrical energy, and the gravitational pull of the material helps to keep the operation running.

Q3 What is the expected lifespan of a coal vibratory feeder?

Generally, the feeder can last for about 10 to 20 years with proper use and regular maintenance.

Q4 What are the latest technologies in coal feeders?

Some recent developments include digital monitoring systems, advanced materials for wear resistance, and eco-friendly designs that reduce carbon footprints.