The following faults and corresponding solutions often occur in the operation of spherical vacuum concentration tanks:
1、 Low vacuum degree fault
Low vacuum degree can lead to an increase in boiling point and a decrease in evaporation efficiency of the concentrate, affecting product quality and equipment capacity. Common reasons and solutions include:
1. Leakage phenomenon: The aging of the sealing ring or loose interface of the tank body causes air infiltration. It is necessary to check the sealing components and replace damaged parts.
2. Insufficient cooling water: The water pressure decreases or the pipeline is blocked. It is necessary to clean the inlet pipeline and adjust the water pump pressure to the normal value.
3. Excessive steam pressure: Heating steam with overpressure accelerates the generation of secondary steam, exceeding the condensation load. The steam pressure should be reduced to the process standard.
4. High cooling water temperature: The inlet water temperature exceeds 30 ℃, which affects the condensation of secondary steam. It is necessary to switch to a low-temperature water source or increase the cooling water flow rate.
5. Vacuum equipment malfunction: The water pump is worn or the valve is leaking, and the vacuum pump needs to be repaired or the pump oil needs to be replaced.
2、 High vacuum degree fault
Excessive vacuum may increase temperature difference but also increase steam consumption, possibly due to abnormal condensation efficiency or equipment blockage.
1. Low cooling water temperature: The low inlet water temperature causes an abnormal increase in vacuum, and the water temperature needs to be adjusted to the range of 25-30 ℃.
2. Insufficient steam pressure: Insufficient steam flow reduces the evaporation rate, and the boiler should be inspected to improve steam supply stability.
3. Poor discharge of condensate: Blockage of the separator or pipeline affects the condensation effect, and the water separator and exhaust pipeline need to be cleaned.
4. Serious scaling of the heater: Coking of the heat transfer surface reduces thermal efficiency, and regular descaling maintenance or reduction of high viscosity material handling should be carried out.
3、 Other operational malfunctions
1. The pump cannot start: power failure or motor damage, the circuit needs to be repaired and the faulty motor needs to be replaced.
2. Abnormal noise or vibration: Bearing wear or impeller imbalance, bearings should be replaced and rotating components calibrated.
3. Temperature control failure: Sensor deviation or poor lubrication, calibration of the instrument and replenishment of lubricating oil are required.
Maintenance suggestion: Regularly check the sealing, monitor cooling water parameters, and avoid overloading to extend equipment life.