Application Case of Hydraulic Lifting Emulsifier Equipment
In the manufacturing sector of high-viscosity chemical products such as adhesives, sealants, and high-concentration coatings, the mixing and emulsification of materials, along with the convenience of equipment operation and maintenance, are crucial factors that impact production continuity and product quality. Traditional fixed emulsifiers often face challenges in handling materials with high viscosity and large particle sizes, and their cumbersome disassembly and cleaning processes lead to prolonged downtime, which restricts the overall production efficiency of enterprises. This case documents the application process of a hydraulic lifting emulsifier in a production line specializing in high-viscosity adhesive manufacturing. It focuses on the equipment's structural characteristics, application scenarios in actual production, operational performance, and the practical benefits it brings to the enterprise, aiming to demonstrate the technical advantages and application value of hydraulic lifting emulsifier equipment in the field of high-viscosity material processing.
1. Production Demand Background and Pre-Equipment Challenges
The production line involved in this case primarily produces high-viscosity polyurethane adhesives, which are widely used in the automotive manufacturing, furniture assembly, and packaging industries. The key production process requires uniform mixing and emulsification of raw materials such as polyols, isocyanates, and fillers (calcium carbonate, talcum powder, etc.) to ensure the adhesive has stable bonding strength, curing speed, and storage stability. Before introducing the hydraulic lifting emulsifier, the production line used a fixed vertical emulsifier with a stirring shaft that could not be lifted or lowered. In the long-term production process, this fixed equipment gradually exposed a series of problems that were difficult to resolve.
Firstly, in the material mixing stage, due to the high viscosity of the polyurethane raw materials (up to 15,000 mPa·s) and the presence of solid fillers with an average particle size of 5-10 μm, the fixed emulsifier's stirring blade could only reach the middle and lower parts of the reaction kettle. The upper layer of materials was unable to be fully stirred, resulting in uneven material mixing. Laboratory testing showed that the solid content deviation of the adhesive in the same batch reached 3-5%, and the filler dispersion uniformity (measured by laser diffraction method) was only 65%, failing to meet the enterprise's internal standard of ≥85% dispersion uniformity. This uneven mixing directly led to inconsistent bonding strength of the finished adhesive, with a strength difference of up to 15% between different samples, and increased product rejection rates.
Secondly, the fixed structure of the equipment made cleaning and maintenance extremely difficult. After each batch of production, the stirring shaft, blades, and the inner wall of the reaction kettle needed to be thoroughly cleaned to prevent cross-contamination between different batches of materials. However, the fixed stirring shaft of the traditional emulsifier meant that workers had to enter the reaction kettle (with a volume of 3 cubic meters) for manual cleaning, which took 4-5 hours per cleaning session. This not only increased the labor intensity of workers but also posed potential safety risks such as confined space operations. Additionally, when the stirring blade or mechanical seal required maintenance or replacement, the entire equipment had to be disassembled, resulting in a maintenance cycle of 2-3 days each time. The long cleaning and maintenance time led to the production line being out of service for up to 8-10 hours per day, significantly limiting the daily output, which was only 8 tons, far below the market demand.
Thirdly, the traditional fixed emulsifier had poor adaptability to different material viscosities. When processing materials with varying viscosity ranges (from 5,000 to 15,000 mPa·s), the fixed stirring speed (1200 rpm) could not be adjusted according to the material characteristics. For low-viscosity materials, excessive stirring speed easily caused material splashing and increased foam content (up to 8% of the finished product), affecting the adhesive's curing performance. For high-viscosity materials, insufficient stirring force led to prolonged emulsification time (up to 3 hours per batch) and increased energy consumption, with a power consumption of 220 kWh per ton of product, significantly increasing production costs.
To address these issues, the enterprise decided to introduce a hydraulic lifting emulsifier, expecting to improve material mixing uniformity, shorten cleaning and maintenance time, and enhance equipment adaptability to different materials through the equipment's lifting function and optimized structural design, thereby improving production efficiency and product quality.
2. Structural Characteristics and Operational Principle of the Hydraulic Lifting Emulsifier
The newly introduced hydraulic lifting emulsifier has a matching reaction kettle volume of 3 cubic meters, which is fully compatible with the original production line's layout. Its core structural features include a hydraulic lifting system, a variable-speed stirring system, a detachable stirring assembly, and an automatic cleaning system. These structures work together to address the limitations of traditional fixed emulsifiers and achieve efficient and flexible production operations.
2.1 Core Structural Features
The hydraulic lifting system is the key component of the equipment, consisting of a hydraulic cylinder, a guide rail, and a control valve group. The hydraulic cylinder has a lifting stroke of 1.8 meters, which can drive the entire stirring assembly (including the stirring shaft, blades, and mechanical seal) to move up and down freely along the guide rail. The lifting speed is adjustable (0.1-0.3 m/min), and the system has a pressure protection function. When the lifting resistance exceeds the set pressure (15 MPa), the system automatically stops to prevent equipment damage. This lifting function eliminates the need for workers to enter the reaction kettle for operations and facilitates the disassembly and maintenance of the stirring assembly.
The variable-speed stirring system is equipped with a frequency converter and a high-torque motor (power of 15 kW), with a stirring speed adjustable in the range of 300-1800 rpm. The system can automatically adjust the stirring speed according to the material viscosity and emulsification stage. For example, during the initial stage of material mixing (with low viscosity), a low speed (300-600 rpm) is used to prevent material splashing; during the emulsification stage (with increased viscosity), a medium to high speed (1200-1800 rpm) is adopted to enhance shearing and mixing effects. Additionally, the stirring blade adopts a multi-layer inclined paddle design (3 layers of blades), with each blade having a 45° inclination angle, which can generate upward and downward material circulation during rotation, ensuring that the upper, middle, and lower layers of materials in the reaction kettle are fully mixed.
The detachable stirring assembly uses a quick-connect flange structure between the stirring shaft and the motor. When maintenance or replacement is required, the flange connection can be disassembled by removing 6 bolts, and the entire stirring assembly can be lifted out of the reaction kettle through the hydraulic lifting system, which takes only 30-40 minutes, significantly shortening the disassembly time. The stirring blades are made of 316L stainless steel, which has excellent corrosion resistance and wear resistance, suitable for long-term contact with chemical raw materials containing fillers.
The automatic cleaning system includes a rotating spray ring installed at the bottom of the stirring assembly and a high-pressure water pump (pressure of 8 MPa). After the production of a batch is completed, the stirring assembly is lifted to a height of 1 meter, and the high-pressure water pump is turned on. The spray ring sprays high-pressure water to the inner wall of the reaction kettle and the surface of the stirring blades at 360°, realizing automatic cleaning. The cleaning time is controlled within 1 hour, and the cleaning effect can reach the enterprise's hygiene standard (no residual material particles visible to the naked eye), eliminating manual cleaning operations.
2.2 Operational Principle in Production Process
In the actual production process of high-viscosity polyurethane adhesives, the hydraulic lifting emulsifier operates in three main stages: material feeding and mixing, emulsification, and post-production cleaning.
In the material feeding and mixing stage, the hydraulic lifting system first lowers the stirring assembly into the reaction kettle, and the stirring shaft is inserted to a position 10 cm above the bottom of the kettle. Then, the raw materials (polyols, isocyanates) are added to the reaction kettle in proportion through the feeding port, and the variable-speed stirring system is set to a low speed (300 rpm) for preliminary mixing. After 10 minutes, the solid fillers (calcium carbonate) are added while stirring, and the stirring speed is gradually increased to 600 rpm. The multi-layer inclined blades drive the materials to form a circular flow in the kettle, ensuring that the fillers are evenly dispersed in the liquid phase without agglomeration.
In the emulsification stage, as the material viscosity increases (reaching 8,000-10,000 mPa·s), the stirring speed is adjusted to 1500 rpm. The high-speed rotating blades generate strong shearing force, breaking the small agglomerates of fillers into individual particles (particle size reduced to 2-3 μm) and promoting the full reaction between polyols and isocyanates. During this stage, the hydraulic lifting system can slightly adjust the height of the stirring assembly (up and down by 20 cm) every 30 minutes to ensure that the materials in the upper part of the kettle, which are prone to static accumulation, are fully involved in the emulsification process. The entire emulsification stage lasts for 1.5 hours, which is 50% shorter than the traditional equipment's emulsification time.
In the post-production cleaning stage, after the finished adhesive is discharged from the reaction kettle, the hydraulic lifting system lifts the stirring assembly to a height of 1 meter. The automatic cleaning system is activated, and the high-pressure spray ring sprays water to clean the inner wall of the kettle and the stirring blades. During the cleaning process, the stirring system operates at a low speed (300 rpm) to ensure that the water flow can cover all surfaces of the blades. After 1 hour of cleaning, the water is discharged, and the stirring assembly is lowered to the bottom of the kettle to prepare for the next batch of production.
3. Operational Performance of the Hydraulic Lifting Emulsifier in Practical Production
After the installation and debugging of the hydraulic lifting emulsifier, the enterprise conducted a two-month trial production. During this period, the operational performance of the equipment was comprehensively tested from the aspects of product quality, production efficiency, equipment maintenance, and energy consumption, and the test results were compared with the data of the traditional fixed emulsifier.
3.1 Significant Improvement in Product Quality
The most obvious effect of using the hydraulic lifting emulsifier is the significant improvement in the uniformity of material mixing and emulsification. Laboratory test data shows that the solid content deviation of the same batch of polyurethane adhesives is reduced from 3-5% (traditional equipment) to 0.8-1.2%, and the filler dispersion uniformity is increased from 65% to 92%, fully meeting the enterprise's internal quality standards. The bonding strength test of the finished product shows that the strength difference between different samples is reduced to less than 5%, and the product qualification rate is increased from 88% (traditional equipment) to 99.2%, significantly reducing the rejection rate and material waste.
In addition, the control of foam content in the product is also optimized. By adjusting the stirring speed according to the material viscosity, the foam content in the finished adhesive is reduced from 8% (traditional equipment) to 2.5%, which effectively avoids the problem of reduced bonding strength caused by foam in the adhesive during the curing process. The storage stability test shows that the adhesive produced by the hydraulic lifting emulsifier has no delamination or sedimentation after 12 months of storage (the traditional equipment's product had delamination after 8 months), improving the product's market competitiveness.
3.2 Substantial Increase in Production Efficiency
The improvement in production efficiency is mainly reflected in the shortening of the production cycle and the reduction of downtime. In terms of the production cycle, the emulsification time per batch is reduced from 3 hours (traditional equipment) to 1.5 hours, and the cleaning time is reduced from 4-5 hours to 1 hour. The total time for one batch of production (including feeding, mixing, emulsification, discharge, and cleaning) is shortened from 8 hours to 4.5 hours. The daily production batches are increased from 2 batches (traditional equipment) to 4 batches, and the daily output is increased from 8 tons to 16 tons, an increase of 100%, which fully meets the enterprise's market order demand.
In terms of downtime reduction, the detachable stirring assembly and hydraulic lifting function significantly simplify the maintenance process. When the mechanical seal of the equipment needs to be replaced, the disassembly and assembly time is reduced from 2-3 days (traditional equipment) to 2-3 hours, and the maintenance frequency is reduced from once every 15 days to once every 60 days. The annual maintenance downtime is reduced from 720 hours (traditional equipment) to 72 hours, and the effective production time of the production line is increased by 15%, further improving the overall production efficiency.
3.3 Reduction in Energy Consumption and Labor Costs
The variable-speed stirring system of the hydraulic lifting emulsifier effectively reduces energy consumption. By adjusting the stirring speed according to the material viscosity, the power consumption per ton of product is reduced from 220 kWh (traditional equipment) to 140 kWh, a reduction of 36.4%. Based on the annual output of 4,800 tons (calculated at 16 tons per day and 300 working days per year), the annual energy saving is 4,800 tons × (220-140) kWh/ton = 384,000 kWh. Calculated at the industrial electricity price of 0.7 yuan/kWh, the annual energy cost saving is 384,000 kWh × 0.7 yuan/kWh = 268,800 yuan.
In terms of labor costs, the automatic cleaning system eliminates the need for manual cleaning operations in the reaction kettle, reducing the number of operators per production line from 4 (2 for production operation and 2 for cleaning) to 2 (only for production operation and monitoring). Based on the monthly salary of 6,000 yuan per worker, the annual labor cost saving is (4-2) × 6,000 yuan/month × 12 months = 144,000 yuan. Additionally, the reduction in manual cleaning also reduces the risk of confined space operations, improving the safety of the production site and reducing the enterprise's safety management costs.
4. Long-Term Application Benefits and Value Manifestation
After the hydraulic lifting emulsifier was officially put into operation for 8 months, the enterprise achieved significant economic benefits and operational improvements, and the long-term application value of the equipment was further demonstrated.
In terms of economic benefits, the increase in production capacity and product qualification rate directly drove the growth of sales revenue. The monthly sales volume of the enterprise increased from 240 tons (before equipment replacement) to 480 tons, and the product price remained stable at 18,000 yuan/ton. The monthly sales revenue increased from 4.32 million yuan to 8.64 million yuan, an increase of 100%. At the same time, the reduction in energy consumption, labor costs, and material waste (due to the reduction in rejection rate) reduced the comprehensive production cost per ton of product from 15,000 yuan to 13,800 yuan, a reduction of 8%. The monthly profit increased from 960,000 yuan (240 tons × (18,000-15,000) yuan/ton) to 2,016,000 yuan (480 tons × (18,000-13,800) yuan/ton), an increase of 110%, significantly improving the enterprise's profitability.
In terms of operational management, the hydraulic lifting emulsifier's intelligent control system (equipped with a touch screen operation interface) realizes the automatic recording and storage of production parameters (stirring speed, lifting height, cleaning time, etc.). The enterprise can trace the production process of each batch of products through the system, which is convenient for quality control and production scheduling. Additionally, the equipment's low maintenance frequency and simple operation reduce the requirements for the technical level of operators, lowering the training cost of new employees and improving the stability of the production team.
In terms of market expansion, the stable product quality and sufficient production capacity enable the enterprise to undertake large-scale orders from automotive manufacturers and furniture enterprises. For example, the enterprise successfully signed a 1,200-ton annual supply contract with a leading automotive interior manufacturer, which would have been impossible to fulfill with the traditional equipment's production capacity. This not only expands the enterprise's market share but also enhances its brand influence in the high-viscosity adhesive industry.
In terms of environmental protection and safety, the automatic cleaning system reduces the consumption of cleaning water (from 5 cubic meters per batch to 2 cubic meters per batch), and the wastewater can be recycled after simple treatment, reducing environmental pollution. The elimination of manual confined space operations reduces the occurrence of safety accidents, and the enterprise has achieved zero safety incidents related to equipment operation and maintenance since the equipment was put into use, creating a safe and environmentally friendly production environment.
5. Summary of Application Effects
The application of the hydraulic lifting emulsifier in the high-viscosity polyurethane adhesive production line has effectively solved the problems faced by the enterprise, such as uneven material mixing, long cleaning and maintenance time, high energy consumption, and low production capacity. The two-month trial production and eight-month formal operation data show that the equipment has significant advantages in improving product quality, enhancing production efficiency, reducing costs, and ensuring safety and environmental protection.
In terms of product quality: The filler dispersion uniformity is increased by 27 percentage points, the product qualification rate is increased by 11.2 percentage points, the foam content is reduced by 5.5 percentage points, and the storage period is extended by 4 months, fully meeting the high-quality requirements of downstream industries for adhesives.
In terms of production efficiency: The daily output is doubled (from 8 tons to 16 tons), the production cycle per batch is shortened by 43.75%, and the annual maintenance downtime is reduced by 90%, significantly improving the production line's operational efficiency and responsiveness to market demands.
In terms of cost control: The power consumption
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