1. Ensure the inside of the extruder is clean and free from any debris before starting the operation. This helps prevent contamination and ensures smooth processing.
2. Verify that the tapered piston is positioned at its farthest point, allowing the discharge opening to be fully open. This setup is essential for proper material flow during the initial phase.
3. Open the steam injection valve at a pressure of 0.2–0.3 MPa to preheat the extruder barrel until the internal temperature reaches above 60°C. This step is crucial for achieving the right conditions for expansion.
4. After preheating, close the steam injection valve and start the main motor. The motor should run smoothly without any unusual vibrations or noises.
5. Begin feeding the raw material into the extruder through the auger. Then, open the steam valve again and adjust the tapered plug to achieve the desired product quality.
6. Once the product output meets the required standard, avoid making sudden changes to the amount of dry material or steam added. Maintain a stable motor load and allow the barrel temperature to reach equilibrium, typically within 15–20 minutes.
7. The ideal cylinder temperature for optimal expansion is between 105°C and 115°C. Adjust the steam input and production rate accordingly to ensure a high-quality, porous final product.
8. Gradually increase the steam supply as needed to maintain product quality while ensuring the motor does not exceed its rated current. Monitoring the motor load is key to efficient operation.
9. During long-term operation, ensure that the feed material is consistently uniform in composition, particle size, moisture content, and temperature. Stability in these factors is critical for consistent performance in the extruder.
10. Steam must enter the extruder directly through the injection valve and mix with the material. Maintain a steady steam pressure, usually around 0.6–0.75 MPa, for optimal processing.
11. The steam flow is manually controlled using a steam injection valve. The valve opening is adjusted based on the number of revolutions during startup, ensuring precise control over the process.
12. Motor power consumption depends on how much force is required to push the material through the extruder. To increase the motor load, you can:
A. Increase the feed rate. B. Reduce the gap of the tapered plug at the discharge port. C. Operate under low humidity conditions to improve material consistency.
13. The puffing temperature can be raised by both frictional heat from the shaft and the injected steam. To increase the temperature:
A. Inject more steam. B. Narrow the tapered gap at the discharge port.
14. Hydraulic tapered plug operation:
A. At startup, the tapered plug should be fully retracted, allowing the largest possible discharge opening.
B. Once the main motor starts, material enters the extruder. Open the steam valve and activate the hydraulic system. Move the manual reversing valve to the forward position, monitor the material consistency and motor current to meet the required standards (output is proportional to current, while current is inversely related to the plug opening). Then return the valve to the neutral position and disconnect the hydraulic motor power.
C. During production, continuously adjust the tapered plug according to the material characteristics, following the same procedure as described in (B).
D. For shutdown: first stop feeding, open the tapered plug, close the steam supply, and allow all material to exit the extruder. Disconnect the hydraulic system power and turn off the main motor. When stopping, make sure the feeding conveyor has stopped, and let the extruder continue to vent any remaining material. Retract the tapered plug to its maximum position for safety.
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