【Project Overview】
The project is an integrated fully automated system consisting of an flake ice-making machine, ice storage warehouse, screw storage system, and pneumatic conveying system. Based on the customer's existing building, a multi-layer design is adopted: the top houses a 30-ton flake ice machine, the middle section features a 10-ton automatic ice storage system, and the bottom includes a pneumatic conveying system, which provides rapid cooling for the customer's reactor.
【Design Features of the Solution】
Automatic Control System
It can be integrated with the existing reactor control system to achieve highly automated temperature control management. The ice delivery system can receive real-time temperature signal feedback and automatically adjust the amount of ice delivered based on these signals, thereby precisely controlling the temperature inside the reactor.
Strictly adheres to chemical industry safety standards, with electrical panels and wiring all constructed using fire-resistant and explosion-proof materials for protection.
30-ton Flake Ice Machine
Optimal Use of Flaked Ice in Chemical Applications
Among various types of ice used in chemical applications, flaked ice is the optimal choice. Compared to other types, flaked ice does not clump due to surface moisture, making it easier to store and transport. Its low temperature and dry characteristics prevent sticking, facilitating long-term stacking and compatibility with pneumatic conveying systems, which simplifies storage and transportation processes.
Flaked ice can reach temperatures as low as -8°C, with a uniform thickness of 1-2mm. The large contact area of flaked ice allows it to rapidly absorb heat, achieving quick cooling effects.
The customized flaked ice machine is equipped with a CSR550-BD compressor, offering a cooling capacity of 225.68 kW and power consumption of 102.02 kW. The control panel is constructed using materials that meet safety and explosion-proof standards for the chemical industry, ensuring operational safety, efficiency, and reliability.
Automated Ice Storage Warehouse
The automated ice storage warehouse is designed to efficiently manage the storage and retrieval of flaked ice, ensuring a steady supply for industrial processes while maintaining optimal conditions for ice quality.
Features of the Automated Ice Storage Warehouse
Bottom Design
The bottom of the ice storage warehouse is designed with a fully screw-driven system. Ice flakes are uniformly propelled forward by the bottom ice conveying screws, preventing accumulation at the bottom and ensuring that the ice remains dry. Motors and bearings are installed outside the warehouse for easy maintenance. The storage warehouse is equipped with an ice-crushing device, ensuring that even if ice blocks clump together, they can still be broken down and conveyed out.
Specifications
• Insulation Material: Double-sided 0.426mm color-coated steel plates
• Insulation Thickness: 100mm
• Dimensions: Length 6m, Width 4m, Height 3.5m
• Design Temperature: -8°C
• Storage Capacity: 10 tons of ice blocks
Key Equipment
• Main Compressor: Bitzer 2CES-3Y, Cooling Capacity 6.25 kW, Power Consumption 43.2 kW, Explosion-proof Electrical Panel
• Six-Unit Spiral Conveyor:
• Dimensions: Length 5.75m × Width 3.75m
• Spiral Blade Diameter: 550mm
• Blade Thickness: 10mm
• Hub Diameter: 245mm × 8mm
• Screw Output Speed: 5.6 r/min
• Power: 5.5 kW (Guomao Explosion-proof Reducer Motor)
• Crusher (Wolf Tooth Bar):
• Length: 3.7m
• Hub Diameter: 140mm × 10mm
• Drive Method: Chain-driven
• One reducer motor drives four Wolf Tooth Bars simultaneously
• Output Speed: 30 r/min
• Power: 4 kW (Guomao Explosion-proof Reducer Motor)
This design ensures efficient and reliable operation, maintaining optimal conditions for ice quality while simplifying maintenance and enhancing safety.
Conveying System
Weighing and Screw Conveyor System
The weighing and screw conveyor system provides precise ice delivery for temperature control in chemical reactions, enhancing the automation level of chemical production and reducing operational risks. The system automatically records ice usage data, facilitating traceability and quality management while optimizing overall workflows.
Weighing System:
Equipped with built-in pressure sensors, the weighing system has a single-load capacity of 250 kg.
Horizontal Screw Conveyor:
• Length: 4.75 meters
• Spiral Blade Diameter: 300 mm
• Blade Thickness: 5 mm
• Hub Dimensions: 89 mm × 10 mm
• Output Speed: 80 r/min
• Power: 4 kW
• Motor: Guomao Explosion-proof Reducer Motor
Inclined Screw Conveyor:
• Length: 3.2 meters
• Inclination Angle: 25 degrees
• Spiral Blade Diameter: 300 mm
• Blade Thickness: 5 mm
• Hub Dimensions: 89 mm × 10 mm
• Output Speed: 60 r/min
• Power: 3 kW
• Motor: Guomao Explosion-proof Reducer Motor
This system ensures accurate and safe ice transportation for chemical processes, supporting efficient production and reliable operation.
Pneumatic Conveying System
The pneumatic conveying system, known for its efficiency, space-saving design, and environmental friendliness, is particularly suitable for the chemical industry. This system uses aerodynamics to quickly transport materials through dedicated pipelines, reducing labor intensity and costs. It not only protects materials from damage and contamination but also performs tasks such as mixing, screening, and cooling during the conveying process, significantly enhancing the level of automation in production processes.The pneumatic conveying system consists of an air pre-cooling system, a Roots blower, diverter valves, cyclone separators, and pipelines.Air Pre-cooling System: Cools air to 5°C to prevent ice blocks from melting and sticking together.
Roots Blower: Provides the necessary airflow for material transportation.
Diverter Valves: Distributes ice blocks to multiple outlets based on reactor requirements.
Cyclone Separator: Separates air from flaked ice.
Pipelines: Made of PE material with thermal insulation treatment.
This system ensures efficient and safe material transportation while maintaining high levels of automation and reliability in chemical processes.
