Photovoltaic sand production line whole plant equipment and solutions
System Overview
This whole-plant system solution for PV sand production line is designed to meet the stringent standards for low-iron quartz sand in the photovoltaic glass industry. The system integrates the complete process of crushing and screening, grinding and grading, desliming and removing impurities, multi-stage magnetic separation and deep pickling and purification, etc. Through precise equipment configuration and automated control system, it ensures that the final product fully meets the requirements of photovoltaic glass manufacturing in terms of key indexes, such as iron content, particle size distribution, chemical purity, etc. The whole line design takes into account the production efficiency and environmental protection standards. The design of the whole line takes into account the production efficiency and environmental protection standards, providing stable and reliable high-quality raw materials for the photovoltaic glass industry.
Detailed process flow of the whole plant
Raw material crushing and screening section
Raw materials are firstly fed into the jaw crusher through vibrating feeder for primary crushing, which crushes the raw ores to below 40mm; then transferred to the cone crusher through belt conveyor for medium and fine crushing, which further processes the materials to below 15mm; the crushed materials are screened by the circular vibrating screen, and the qualified granularity enters the next process, and the super-granular materials are returned to the crusher to form a closed-circuit cycle.
Grinding and grading section
After crushing and screening, the qualified materials enter the rod mill for wet grinding, and the particle size distribution of the products is controlled by adjusting the concentration of grinding and the ratio of steel rods; the slurry after grinding is transported to the hydraulic classifier through the pumping system to carry out precise grading, and the difference in settling speed of the particles in the water flow is utilized to realize the effective separation of the target particle size of 26-150 mesh to ensure that the concentration of the product size distribution reaches the requirements of the process.
Desliming and decontamination purification section
The graded slurry enters the desliming processing system, firstly through the spiral washer to remove the clay impurities in the raw materials, and then into the desliming hopper for fine particle separation, effectively removing the micro-fine slime components that affect the purity of the product; the wastewater generated in the process of desliming enters the water treatment system for recycling, which realizes the efficient use of water resources and environmentally friendly production.
Multi-stage magnetic separation and iron removal section
The material after desliming passes through the three-stage magnetic separation system in turn: firstly, it passes through the medium-strength magnetic separator to remove the strong magnetic iron minerals, and then it enters into the high-gradient magnetic separator to remove the medium magnetic impurities in depth; the synergistic effect of the multi-stage magnetic separation process reduces the iron content in the raw material to the lowest level and creates favorable conditions for the subsequent pickling process.
Deep pickling and purification section
After magnetic separation, the concentrate enters the pickling and purification system, and is chemically treated in depth in a closed pickling reactor at a constant temperature of 65°C. The special acid formula and aerodynamic tumbling technology ensures that the materials are in full contact and reaction with the acid, which effectively dissolves the iron impurities on the surface of the particles and in the fissures; after the reaction is completed, the acid is discharged to the recycling tank for recycling and reuse, which greatly reduces the consumption of medicament and the cost of wastewater treatment.
Dehydration, drying and packaging section
After acid washing, the clean silica sand is separated from solid and liquid by high efficient dewatering screen, and then enters into low temperature drying system to remove the surface water, the whole process strictly controls the temperature to avoid the loss of whiteness of the product; the final product is measured, filled and sealed by the automated packaging system to ensure that it is not subjected to secondary contamination during the storage and transportation process.
Core advantages of the whole plant system
Advantage of process integrity
The whole line adopts the integrated design of the whole process, from raw material crushing to finished product packaging, each process is closely connected, and the process parameters are optimized to ensure the stable operation of the system and the consistency of product quality; the modular equipment layout not only ensures the smoothness of the production, but also reserves enough space for the subsequent expansion of production capacity.
Quality Control Advantages
The raw material particle size is controlled by multi-stage crushing and screening, and the combination of wet grinding and precise grading technology ensures that the product particle size distribution is centralized; the deep iron removal process combining physical magnetic separation and chemical pickling is adopted, so that the iron content of the final product is stably controlled at less than 80 ppm, which fully meets the raw material standards of the photovoltaic glass industry.
Advantage of environmental protection and energy saving
The system adopts recycled water design to achieve zero wastewater discharge; equipped with perfect dust collection and treatment facilities to ensure that the dust emission during the production process meets the requirements of environmental protection; the energy consumption has been optimized and designed so that the energy consumption per unit of product is at the advanced level in the industry.
Whole Plant Planning and Configuration
Production area planning
The raw material yard is located at the entrance of the plant, which is convenient for raw material entry and storage; the crushing and screening section and the grinding and grading section are arranged adjacent to each other to reduce the material transfer distance; the purification processing area is centrally arranged with magnetic separation and pickling equipment to ensure the coherence of the process; the finished product storage area is independently set up to avoid the products from being contaminated.
Auxiliary system configuration
The water supply system is equipped with complete water treatment facilities to realize the recycling of production water; the electric power system adopts double circuit power supply design to ensure continuous and stable production; the environmental protection system includes dust collection, waste water treatment and noise control facilities to meet the requirements of environmentally friendly production; the central control room centrally monitors the operation status of each process to realize intelligent production management.
Quality Control System
A strict quality inspection system is established for incoming raw materials to ensure that the raw materials meet the requirements of the production process; the whole production process is subject to quality control, and key processes are set up with quality inspection points; finished products are subject to a comprehensive quality inspection before leaving the factory, and a perfect quality traceability system is established to ensure that each batch of products can be traced back to the production process.
Through scientific and reasonable process design, reliable equipment configuration and perfect quality control system, this whole-plant solution provides the PV glass industry with a professional PV sand production overall solution, ensuring that the products fully meet the strict requirements of PV glass manufacturing in terms of iron content, particle size distribution, chemical purity and other key indicators, while realizing the goals of efficient, environmentally friendly and stable industrialized production.
