Application and Efficiency Analysis of Vibrating Screening Equipment in Feed Processing

Mechanical screening is the most commonly used method in feed mills for separating materials based on particle size. The core component of vibrating screen equipment is the screen surface, which typically comes in two forms: steel plate punched screens and woven screens. These are widely adopted in the industry. Pig net users often discuss the application of screening technology in feed processing, covering key aspects and general calculation methods. The use of screening technology in feed production mainly focuses on two areas: removing impurities from raw materials and classifying them or finished products by particle size. This includes cleaning raw materials of impurities, classifying crushed materials, screening before granulation, and grading granulated products. The effectiveness of screening has a significant impact on both the quality and yield of feed products. **1. Screening Efficiency and Its Influencing Factors** **1.1 Screening Efficiency** Screening efficiency involves two main metrics: the retention rate of the desired material on the screen and the retention rate of the material that should pass through the screen. These factors influence the removal of impurities, the loss of raw materials during cleaning, and the accuracy of classification in product sizing. The former is referred to as the screening rate (η1), while the latter is called the erroneous screening rate (η2). The formulas are as follows: η1 = (w1 / w2) × 100% η2 = (w3 / w4) × 100% Where: - η1 = Screening rate (%) - η2 = Erroneous screening rate (%) - w1 = Amount of expected material retained on the screen (kg/h) - w2 = Total amount of expected material (kg/h) - w3 = Amount of expected material that remains on the screen (kg/h) - w4 = Total amount of material passing through the screen (kg/h) These metrics help evaluate the efficiency of the screening process. When the screen is used for impurity removal, η1 represents the impurity removal rate, and η2 reflects the loss of the desired material. **1.2 Factors Affecting Screening Performance** Several factors influence the efficiency of screening. One important factor is the maximum particle diameter that can pass through the mesh, which can be estimated using the formula: d = D cos α - e sin α Where: - d = Maximum particle diameter that can pass through the mesh (mm) - D = Mesh diameter (mm) - e = Wire diameter (mm) - α = Screen inclination angle This formula provides an estimate of the critical particle size, but actual passage depends on other conditions such as particle shape, sieve geometry, and material properties. **1.2.1 Particle and Mesh Shape** The calculation assumes spherical particles and circular mesh holes. However, in real feed production, materials often consist of cylindrical or irregularly shaped particles, and the mesh holes may be round or rectangular. The way particles interact with the mesh significantly affects their ability to pass through. For example, a 4×10 mm particle can pass through a 5 mm hole when aligned vertically but not when placed horizontally. Therefore, particle passage is somewhat random and requires statistical analysis. Generally, rectangular meshes perform better with cylindrical particles, while round holes are more effective for irregularly shaped particles with uniform dimensions. **1.2.2 Screen Opening Ratio** A higher opening ratio improves the screening performance. Woven screens typically offer a higher opening ratio than punched screens, assuming structural strength is maintained. As a result, woven screens tend to have better performance in terms of material flow and throughput. **1.2.3 Material Layer Thickness** The thickness of the material layer on the screen plays a crucial role in screening efficiency. If the layer is too thick, smaller particles in the upper layer may not pass through the mesh, increasing the false screening rate and reducing yield. Conversely, if the layer is too thin, the screen’s capacity is underutilized. The optimal thickness must be determined experimentally. Adjustments in screen angle and vibration amplitude can also influence the ideal layer thickness. **1.2.4 Screen Movement Pattern** Effective screening requires proper relative motion between the material and the screen surface. This can be achieved through horizontal reciprocating motion, vertical reciprocating motion, or a combination of both. Screens that only move in one direction may lead to uneven material distribution. In practice, rotary vibrating screens that combine both motions provide better screening results. **1.2.5 Material Properties** The physical characteristics of the material—such as particle size, moisture content, friction, and flowability—significantly affect screening performance. Larger differences in particle size make screening easier. Higher moisture content increases internal and external friction, reducing flowability and making it harder for particles to pass through the mesh. Therefore, it's essential to adjust process parameters according to the specific properties of the material to achieve optimal screening results.

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