Application and Efficiency Analysis of Vibrating Screening Equipment in Feed Processing

Mechanical screening is a fundamental technique used in feed mills for separating and classifying materials. The core component of vibrating screen equipment is the screen surface, which typically consists of either steel plate punched screens or woven screens. These types of screens are widely adopted due to their efficiency and durability. In the context of pig feed production, understanding the application of screening technology is essential for optimizing both quality and productivity. The use of screening in feed processing primarily focuses on two key areas: removing impurities from raw materials and classifying them based on particle size. This includes tasks such as cleaning raw materials, sorting crushed materials, and grading granulated products. The effectiveness of screening during processing plays a crucial role in determining the final quality and yield of feed products. **1. Screening Efficiency and Its Influencing Factors** **1.1 Screening Efficiency** Screening efficiency is measured by two main indicators: the retention rate of material that should stay on the sieve (expected material) and the retention rate of material that should pass through the sieve (expected material). These metrics directly affect the removal of impurities, the loss of valuable material during cleaning, and the accuracy of particle size classification. The first is known as the screening rate (η1), while the second is referred to as the missing rate (η2), calculated using the following formulas: η1 = (w1 / w2) × 100% η2 = (w3 / w4) × 100% Where: - η1 = Screening rate (%) - η2 = Missing rate (%) - w1 = Amount of expected material retained on the sieve (kg/h) - w2 = Total amount of expected material (kg/h) - w3 = Amount of expected material that remains on the sieve (kg/h) - w4 = Total amount of expected material passing through the sieve (kg/h) These values are essential for evaluating the performance of the screening process. When the sieve is used for impurity removal, η1 corresponds to the impurity removal rate, and η2 reflects the loss of the desired material. **1.2 Factors Affecting Screening Performance** Several factors influence the effectiveness of the screening process. One important consideration is the maximum particle diameter that can pass through a mesh, which can be estimated with 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 does not account for all variables affecting particle passage. Other factors, such as particle shape, mesh design, and material characteristics, also play a significant role. **1.2.1 Particle and Mesh Shape** The calculation assumes spherical particles and circular mesh openings. However, in real-world applications, feed materials often consist of cylindrical or irregularly shaped particles. The type of mesh—whether round or rectangular—can significantly impact how well particles pass through. For example, cylindrical particles may pass through a round mesh when oriented vertically but not when lying horizontally. Therefore, the passage of particles is often probabilistic and must be analyzed statistically. **1.2.2 Screen Opening Ratio** The opening ratio of the screen surface refers to the proportion of the area available for material to pass through. A higher opening ratio generally results in better screening performance. Woven screens tend to have a higher opening ratio than punched screens, leading to improved efficiency, provided the structural integrity of the screen is maintained. **1.2.3 Material Layer Thickness** The thickness of the material layer on the screen has a direct impact on screening efficiency. If the layer is too thick, smaller particles may become trapped, increasing the false screening rate and reducing product yield. Conversely, if the layer is too thin, the throughput may decrease. The optimal thickness depends on factors like screen angle and vibration amplitude. In practice, uneven feeding can cause localized thickening, which negatively affects screening performance. **1.2.4 Screen Movement State** Effective screening requires proper relative motion between the material and the screen. This motion can be horizontal, vertical, or a combination of both. Screens that only move in one direction may not perform as well as those that combine both movements. Rotating vibratory screens, for instance, often provide superior results due to their ability to maintain even material distribution and improve screening efficiency. **1.2.5 Material Characteristics** The physical properties of the material being screened, such as particle size, moisture content, friction, and flowability, significantly influence the screening process. Larger differences in particle size make separation easier, while high moisture content can reduce fluidity and hinder particle passage. To achieve the best results, it's important to adjust process parameters according to the specific characteristics of the material.

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