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Dryer failure solution - Huaqiang Electronic Network
The drying process of plastic granules, while seemingly straightforward, can sometimes fall short of achieving complete dryness. Several factors influence the effectiveness of this process:
1. **Airflow and Filtration**: Proper airflow is essential for efficient drying. The dryer removes moist air, leaving only a minimal amount of moisture behind. Then, the air is heated to lower its relative humidity. This dry air has a low vapor pressure, allowing water molecules inside the granules to break free from their binding forces and diffuse into the surrounding air. During inspection, it's crucial to check the air filters and hoses. A clogged filter or a collapsed hose can restrict airflow, reducing the dryer’s efficiency. A damaged filter may also contaminate the desiccant, limiting its ability to absorb moisture effectively.
2. **Temperature Control**: Heat plays a vital role in breaking the bond between water molecules and hygroscopic polymers. When the temperature rises above a certain threshold, the attraction between water and the polymer chains weakens, allowing the moisture to be carried away by the dry air. It's important to monitor the temperature at the silo inlet to account for heat loss through the hose. If the air entering the silo is too cold, it could indicate issues such as improper controller settings, poor insulation, or faults in the heater element, contactor, thermocouple, or control system.
3. **Drying Time**: The process of heat absorption and moisture diffusion to the surface of the particles takes time. Therefore, resin suppliers should provide specific guidelines on the effective drying time required for each material at the correct temperature and dew point. This ensures that the granules are fully dried before being used in production.
4. **Gas Flow and Residence Time**: Dry hot air transfers heat to the granules in the silo, removing moisture from their surfaces and returning it to the dryer. Sufficient gas flow is necessary to maintain the required drying temperature over a set period. After the granules leave the dryer, the silo must have enough space to allow for adequate drying time. Effective drying time refers to the period during which the granules are exposed to the right temperature and humidity conditions. If the residence time is too short, proper drying cannot be achieved. The size and shape of the pellets or crushed materials can affect bulk density and, consequently, the drying time.
By ensuring all these factors are properly managed, the drying process can be optimized, leading to better quality and performance of the final product.