木质生物质粉碎及规模化制粉机械设计及理论研究
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摘要
规模化粉碎处理是木质生物质能源开发利用及产业化的重要环节。但迄今为止,市场上还难以采购到适用于木质生物质大规模粉碎生产的粉碎机械,针对木质生物质原料的粉碎理论和规模化制粉机械设计的专门研究尚不多见,结果造成木质生物质能源规模化利用及产业化面临实际困难。因此针对木质生物质的特性进行粉碎理论与粉碎生产流程研究,尽快研制出高效、低能耗的规模化制粉机械与装备势在必行。
本文较全面、系统地综述了粉碎技术及生物质粉碎设备的国内外研究现状及存在的问题,分析确定了常见木质生物质利用方式的适用粉碎粒度。在对木质生物质的基本物性进行分析的基础上,提出了木质生物质的粉碎模型是体积粉碎模型和表面粉碎模型的叠加；研究、建立了木质生物质粉碎过程的矩阵模型及粉碎动力学模型。进行了木质生物质含水率及密度的测定实验以及木质生物质粉碎试验,得出了原料密度、预处理方式对木质生物质粉碎特性的影响及规律,为木质生物质粉碎生产流程的确定以及粉碎机械的设计提供了理论依据。
根据木质生物质的基本物性以及木质生物质粉碎原理,分析、确定出毫米级目标粒径的木质生物质粉碎方法；在分析原料收集方式、干燥方法以及粉碎级数等因素对木质生物质粉碎生产过程影响的前提下,提出了8种可行的粉碎生产流程；进而应用权衡分析工具Pugh矩阵法进行评价、确定了理想的粉碎生产流程；并据此结果,为年产3000吨生物燃油生产线制定出了合理的规模化制粉工艺流程。
鉴于TRIZ理论具有能够帮助设计人员在概念设计阶段迅速发现主要问题并提供解决问题的相应原理,有效减少传统试错法所耗费的时间和精力,提高设计效率和设计质量的优点,本文应用TRIZ理论,以安全、高效、细粉碎及低功耗为目标,进行了制粉机创新概念设计研究,得出了12个概念方案,并对其进行了系统综合和评价,确定出轴向振筛式结构为制粉机概念设计的最终方案,双层筛式结构和双转子结构为两个备选方案。
对规模化制粉机械的粉碎机理进行了研究,提出了木质生物质粉碎过程中物料断裂的基本形式,建立了裂纹自动扩展的判据；研究分析了粉碎过程中物料有效碰撞方式及物料碰撞时的有效受力,建立了物料颗粒间有效碰撞的运动模型,为规模化制粉机械的设计提供了理论依据。
根据理论分析和试验结果,创新性地提出了沿转子轴向振动的振筛式木质生物质制粉机整机设计方案。该设计方案具有筛分效率高、筛网寿命长、无需严控振幅、操作调整方便、整机安全性好的优点。
对制粉机的关键部件进行了虚拟样机仿真研究。通过几何仿真确定出了转子部件的合理结构；运用有限元分析软件ANSYS对锤片进行了不同载荷下的受力分析,对主轴进行了静力学分析和模态分析；对制粉机的转子系统进行了动态特性分析,计算出转子系统的临界转速状态；运用动力学仿真软件ADAMS对转子进行了动平衡分析；结果表明,该制粉机关键部件的设计及安全可靠性符合要求。
本文的研究方法和研究结果可为木质生物质粉碎机械的设计及其理论研究提供借鉴,为高效、低能耗木质生物质粉碎技术与装备的研发提供技术支持或参考,对推动木质生物质粉碎技术的进步具有一定的参考价值。
Scale comminution is a necessary link for the utilization and industrialization of woody-biomass energy. However so far, there are not pulverizers which are suitable for large-scale production of crushing woody-biomass on the market, and the study on theory of pulverized woody-biomass and large-scale milling equipment is few, which lead to the large-scale and industrial use of woody-biomass energy face practical difficulties. Therefore, it is imperative to take in the study of comminution theory and process on the characteristics of woody-biomass, in order to gain the manufacturing large-scale milling equipments which have higher efficiency and lower power consuming as soon as possible.
In this paper, research status on comminution technology and equipment in domestic and abroad was summarized, appropriate particle size for usual utilization of woody-biomass was made sure. Based on the analysis to the basic physical properties, which comminution model of woody-biomass is the superposition of the volume comminution model and the surface comminution has been brought forward. Matrix model of pulverized process and dynamic model of comminution have been established. Experiment for measure moisture content and density of woody biomass and test for pulverized performance of woody biomass were carried on, the influence of the density and pretreatment of raw materials to comminution characteristics of woody biomass has been derived, which provided the reference for decision-making production process of woody-biomass, and the design of comminution machinery.
The comminution method for powder size of millimeter is determined according to the basic physical properties as well as comminution model of woody-biomass. Based on the analysis of raw material gathering, drying methods and the series of comminution, eight kinds of comminution process were put forward, the optional comminution process was decision-making out by Pugh matrix evaluation, and then a reasonable scale milling process for the bio-oil production line with the annual throughput of 3,000 tons was established.
In the light of TRIZ (Theory of Inventive Problem Solving) in the conceptual design of the equipments can help the designer to discover the main problem quickly and provide principles for solving the problem improving the efficiency and the level of the design consumedly, the innovative conceptual design for woody biomass mill with safety, small powder size,higher efficiency and lower power consuming was directed by the methodology of TRIZ, and twelve conceptual projects were acquired. After the evaluation and synthesis to conceptual schemes, the final project(axial vibration sieve-type) and two storage projects(double-screener and dual-rotor structure) were determined.
Study on comminution mechanism of the scale milling machine was made, the basic fracture forms of woody-biomass were put forward and the qualification of the crack automatic extension was established. Research and analysis of the material effective impact way and effective stress were made, movement model of effective impact between powders was established, which provided the reference for the design of scale comminution machinery.
According to the theoretical study and experimental results, the structural design of axial vibration sieve-type milling machine was conducted. Innovative design of vibrating screen, which vibrating along the rotor axial can not only improve the screening efficiency, but avoid the hammer-break screen and extend the screen life as well as. Without controling amplitude strictly, makes the operation easy to adjust, reduce costs and increase of security.
Virtual prototype simulation research on key components of milling machine was conducted. The structure of the rotor components was determined according to geometric simulation. Hammer static analysis, spindle static analysis and vibration mode analysis were directed based on ANSYS, research on dynamic characteristics of rotor and critical speed was made sure, rotor dynamic balance analysis was conducted based on ADAMS, which verify the safety and reliability of the design of the milling machine.
The research methods and results could provide reference for the design and theoretical study on woody-biomass comminution machinery, and provide technical support or reference for the research on comminution technology and equipment of woody-biomass with higher efficiency and lower power consuming, as well as has certain reference value to promote the progress of woody-biomass comminution technology.
本文较全面、系统地综述了粉碎技术及生物质粉碎设备的国内外研究现状及存在的问题,分析确定了常见木质生物质利用方式的适用粉碎粒度。在对木质生物质的基本物性进行分析的基础上,提出了木质生物质的粉碎模型是体积粉碎模型和表面粉碎模型的叠加；研究、建立了木质生物质粉碎过程的矩阵模型及粉碎动力学模型。进行了木质生物质含水率及密度的测定实验以及木质生物质粉碎试验,得出了原料密度、预处理方式对木质生物质粉碎特性的影响及规律,为木质生物质粉碎生产流程的确定以及粉碎机械的设计提供了理论依据。
根据木质生物质的基本物性以及木质生物质粉碎原理,分析、确定出毫米级目标粒径的木质生物质粉碎方法；在分析原料收集方式、干燥方法以及粉碎级数等因素对木质生物质粉碎生产过程影响的前提下,提出了8种可行的粉碎生产流程；进而应用权衡分析工具Pugh矩阵法进行评价、确定了理想的粉碎生产流程；并据此结果,为年产3000吨生物燃油生产线制定出了合理的规模化制粉工艺流程。
鉴于TRIZ理论具有能够帮助设计人员在概念设计阶段迅速发现主要问题并提供解决问题的相应原理,有效减少传统试错法所耗费的时间和精力,提高设计效率和设计质量的优点,本文应用TRIZ理论,以安全、高效、细粉碎及低功耗为目标,进行了制粉机创新概念设计研究,得出了12个概念方案,并对其进行了系统综合和评价,确定出轴向振筛式结构为制粉机概念设计的最终方案,双层筛式结构和双转子结构为两个备选方案。
对规模化制粉机械的粉碎机理进行了研究,提出了木质生物质粉碎过程中物料断裂的基本形式,建立了裂纹自动扩展的判据；研究分析了粉碎过程中物料有效碰撞方式及物料碰撞时的有效受力,建立了物料颗粒间有效碰撞的运动模型,为规模化制粉机械的设计提供了理论依据。
根据理论分析和试验结果,创新性地提出了沿转子轴向振动的振筛式木质生物质制粉机整机设计方案。该设计方案具有筛分效率高、筛网寿命长、无需严控振幅、操作调整方便、整机安全性好的优点。
对制粉机的关键部件进行了虚拟样机仿真研究。通过几何仿真确定出了转子部件的合理结构；运用有限元分析软件ANSYS对锤片进行了不同载荷下的受力分析,对主轴进行了静力学分析和模态分析；对制粉机的转子系统进行了动态特性分析,计算出转子系统的临界转速状态；运用动力学仿真软件ADAMS对转子进行了动平衡分析；结果表明,该制粉机关键部件的设计及安全可靠性符合要求。
本文的研究方法和研究结果可为木质生物质粉碎机械的设计及其理论研究提供借鉴,为高效、低能耗木质生物质粉碎技术与装备的研发提供技术支持或参考,对推动木质生物质粉碎技术的进步具有一定的参考价值。
Scale comminution is a necessary link for the utilization and industrialization of woody-biomass energy. However so far, there are not pulverizers which are suitable for large-scale production of crushing woody-biomass on the market, and the study on theory of pulverized woody-biomass and large-scale milling equipment is few, which lead to the large-scale and industrial use of woody-biomass energy face practical difficulties. Therefore, it is imperative to take in the study of comminution theory and process on the characteristics of woody-biomass, in order to gain the manufacturing large-scale milling equipments which have higher efficiency and lower power consuming as soon as possible.
In this paper, research status on comminution technology and equipment in domestic and abroad was summarized, appropriate particle size for usual utilization of woody-biomass was made sure. Based on the analysis to the basic physical properties, which comminution model of woody-biomass is the superposition of the volume comminution model and the surface comminution has been brought forward. Matrix model of pulverized process and dynamic model of comminution have been established. Experiment for measure moisture content and density of woody biomass and test for pulverized performance of woody biomass were carried on, the influence of the density and pretreatment of raw materials to comminution characteristics of woody biomass has been derived, which provided the reference for decision-making production process of woody-biomass, and the design of comminution machinery.
The comminution method for powder size of millimeter is determined according to the basic physical properties as well as comminution model of woody-biomass. Based on the analysis of raw material gathering, drying methods and the series of comminution, eight kinds of comminution process were put forward, the optional comminution process was decision-making out by Pugh matrix evaluation, and then a reasonable scale milling process for the bio-oil production line with the annual throughput of 3,000 tons was established.
In the light of TRIZ (Theory of Inventive Problem Solving) in the conceptual design of the equipments can help the designer to discover the main problem quickly and provide principles for solving the problem improving the efficiency and the level of the design consumedly, the innovative conceptual design for woody biomass mill with safety, small powder size,higher efficiency and lower power consuming was directed by the methodology of TRIZ, and twelve conceptual projects were acquired. After the evaluation and synthesis to conceptual schemes, the final project(axial vibration sieve-type) and two storage projects(double-screener and dual-rotor structure) were determined.
Study on comminution mechanism of the scale milling machine was made, the basic fracture forms of woody-biomass were put forward and the qualification of the crack automatic extension was established. Research and analysis of the material effective impact way and effective stress were made, movement model of effective impact between powders was established, which provided the reference for the design of scale comminution machinery.
According to the theoretical study and experimental results, the structural design of axial vibration sieve-type milling machine was conducted. Innovative design of vibrating screen, which vibrating along the rotor axial can not only improve the screening efficiency, but avoid the hammer-break screen and extend the screen life as well as. Without controling amplitude strictly, makes the operation easy to adjust, reduce costs and increase of security.
Virtual prototype simulation research on key components of milling machine was conducted. The structure of the rotor components was determined according to geometric simulation. Hammer static analysis, spindle static analysis and vibration mode analysis were directed based on ANSYS, research on dynamic characteristics of rotor and critical speed was made sure, rotor dynamic balance analysis was conducted based on ADAMS, which verify the safety and reliability of the design of the milling machine.
The research methods and results could provide reference for the design and theoretical study on woody-biomass comminution machinery, and provide technical support or reference for the research on comminution technology and equipment of woody-biomass with higher efficiency and lower power consuming, as well as has certain reference value to promote the progress of woody-biomass comminution technology.
引文
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