Troubleshooting Uneven Briquette Density
Material Consistency Checks
- Particle Size: Maintain uniform size (1-5mm) through pre-screening. Coarse particles create voids; fines cause compaction issues.
- Moisture Content: Keep 6-12% for biomass. Adjust with drying/humidifying systems to optimize binding and friction.
Feeding System Optimization
- Uniform Feeding: Calibrate feeder speed for consistent material flow into compression chamber.
- Pre-Compaction: Install pre-compression screw/auger to distribute material evenly and reduce air pockets.
Compression Parameter Adjustments
- Pressure Settings: Increase for low-density materials (e.g., sawdust); decrease for high-density (e.g., coal). Target 6:1-10:1 compression ratio.
- Dwell Time: Extend pressure duration using adjustable eccentric drives or servo motors for better uniformity.
Tooling Inspection & Maintenance
- Die Wear: Replace dies when wall thickness deviation exceeds 10% to prevent pressure loss.
- Punch Alignment: Verify alignment with dial indicators; adjust guide rails as needed.
Die Design Modifications
- Tapered Dies: Implement 2-5° taper for progressive compression from entry to exit.
- Die Length: Increase for higher compaction while balancing energy efficiency.
System Calibration
- Pressure Gauges: Regularly calibrate to ensure accurate pressure readings.
- Seal Integrity: Replace worn hydraulic cylinder seals to maintain consistent pressure.
Pro Tip: Always document adjustments and their effects on density to build a knowledge base for future troubleshooting.