In China's steel drum manufacturing enterprises, most of them are still edging processes on the production line. The barrel body edging process is a kind of barrel edge welding edge treatment process. The barrel edge welding edge treatment is to pre-treat the barrel body plate joints before the seam welding, and the purpose thereof is mainly to eliminate the oxides on the edges. Oil, etc., in order to facilitate seam welding; followed by to reduce the thickness of the edge, in order to facilitate the quality of the process after the guarantee. At present, the main domestic process method is edging, that is, using 4 to 8 sets of grinding machines for welding edge grinding, barrel making industry known as edging process.
People who witnessed the edging production will be shocked because the working environment here is too bad, there are deafening noises, there are diffuse dust, there is smoke gas smoke ... ..., noise from friction between the wheel and the steel plate; Dust is the grinding of the grinding wheel and steel plate; part of the flue gas is the product of the binder in the grinding wheel at high temperature, and part of the result is the result of vaporization of the oil on the surface of the drum at high temperature. In such a working environment, environmental protection department inspections will often require rectification as soon as possible, but so far it has not changed much. Why is this? Because the process works well, it does not require much investment.
So, how can we reduce the dust from the milling process? Or let us first see how smoke is formed.
First, smoke and dust generation and harm
In the edging production process, the air in the workshop is full of smoke and dust. Smoke and dust are tiny particulate matter. Dust is a granular waste formed by the friction between the grinding wheel and the steel plate. Smoke is formed by the condensation of steam generated by the oil on the steel plate and the organic matter in the grinding wheel, especially when the galvanized sheet is processed. The zinc is heated and oxidized into particles of zinc oxide. Harmful. After the particulate matter enters the air, the diameter of more than 10 microns will settle down quickly due to the action of gravity, but only in the air near the grinding wheel will there be relatively stable high-concentration coarser particles, and the finer particles will have a longer time. Floating in the air, these particulate matter can cause the failure of the grinding wheel motor and transmission system and cause diseases in the human body. People work in a dusty environment can also affect work efficiency.
After the body inhales particulate matter, it may cause pneumoconiosis, alveolitis, bronchitis, occupational asthma, metal fume fever, poisoning, and cancer. In addition, particulate matter can affect human lung function, and some particulate matter can also cause dermatitis and conjunctivitis.
Second, the basic dust prevention measures
In the workshop, even if measures are taken to control fumes, some fumes will inevitably be scattered. Some of these fumes dispersed in the working environment with the air flow are deposited on the top beams, walls, equipment surfaces, etc. After it has accumulated to a certain extent, due to mechanical vibration and other reasons, it may fall again, float in the air, and spread to the breathing area of ​​workers. These floating dusts are sometimes much higher than the fumes produced by daily operations.
In order to avoid the above situation, it is better to install the flowering board in the workshop with soot, so that the roof beam will not be exposed, and there will be no pipes and no wiring below the ceiling; the walls, window frames, etc. should also adopt a structure that is difficult to accumulate smoke. The floor and the wall surface are preferably joined with a suitable arc for cleaning.
If there is a lot of smoke deposited on the floor of the workplace in a short period of time, the floor can be constructed in a lattice and the lower part is dusted with a local suction device.
Workplace equipment layout and smoke control are also related. If the equipment is properly arranged and the size of the passage is appropriate, it is convenient to fully implement the smoke control measures. During the design, efforts should be made to simplify and enhance the continuity of the process system and minimize the chance of dust generation.
Dust emitting equipment and non-dusting equipment should be located in different workshops or completely isolated by partition walls to limit the spread of smoke and dust and minimize the impact on other work environments.
As far as the characteristics of the edging process are concerned, among the technologies that can achieve the same technological effect, the technology that emits the least dust should be used; the economy cannot be ignored, but it should not be based only on direct economics, but on the basis of fumes. The hazards all take into account the comprehensive economics that go into selecting the production technology. The following dust prevention measures can be taken in production technology:
1, choose the appropriate raw materials
In the past, there were many manufacturers who did not consider the harmfulness of the grinding wheel's material so much that they used harmful substances. In the future, we should pay attention to the use of other raw materials instead. The deciding conditions for this choice are: Substitutes should be much less harmful than the original substances; Substitutes cannot significantly reduce the quality of the product or process as compared to the original; The production costs of using substitutes are not higher or higher than the original. Not much; the supply of substitutes should be stable.
The use of silicon carbide, corundum, etc. instead of sandstone with high free silica content as the grinding wheel is a representative example of the use of substitutes.
2, closed
If the process of dust generation is completely sealed, fumes can be prevented from spreading to the working environment. However, it is practically difficult to completely seal the dust due to the operation. Therefore, a partial suction is generally applied to the airtight hood, so that the clean air outside the hood flows into the hood to prevent the escape of dust-laden air currents.
In addition to sealing or semi-enclosed dust-laden equipment, it is also possible to conversely seal the surrounding environment of workers in a dust-laden environment. For example, in a large number of smoke-emitting workshops, it is difficult to take thorough measures to prevent pollution, and the worker's operating room can be sealed and fresh air can be sent to the room.
3, automation
The use of automation or long-distance operation has a significant effect on the prevention of smoke and dust, because the workers do not need to directly participate in the operation of the distribution of smoke and dust, and they can achieve complete sealing and dust collection. However, when it is necessary to enter the interior of the equipment for maintenance, it may encounter high concentrations of dust. At this time, personal protective equipment must be used.
Third, the common ventilation method dust
Ventilation is fully ventilated and partially inhaled. The use of comprehensive ventilation to control dust is mainly used to clean air and gently, continuously dilute the harmful substances in the air of the production site so that it does not exceed the allowable concentration. Therefore, it is also called diluted ventilation. Full ventilation generally requires a much larger amount of air than a partial inhalation, so it is not as economical as a partial inhalation. Drum milling workshops use full ventilation to control fumes. Because there are generally eight wheel sets and they are relatively decentralized, it is difficult to provide local suction devices in terms of process and operation.
Partial inhalation sucks it away from the source before it is released into the air in the workers breathing zone. The local suction device consists of a suction hood, a pipe, an air purifier, and a fan. When used for vacuuming, the air purifier is a dust collector.
Houses that use dust extraction devices to remove dust should send the outdoor air to the workshop under controlled conditions to replace the discharged air, especially when the air intake is relatively large. There will be problems such as the effect of vacuuming, the inability of the room to keep workers comfortable or cold winds blowing on workers. The amount of supplemental air is at least equal to the total amount of air discharged from the workshop by the suction ventilation system, preferably a little more, to minimize air leakage around the building.
When you add air in winter, you must heat it, and in summer, you need to cool it. Therefore, when designing a local air-suction system, you should pay attention to: inspiratory quantity should be minimized on the premise of assuring air-inhaling effect, or air should be recycled, but this should not be caused by circulating air. Endangering the health of employees is a prerequisite.
The soot-laden air that is sucked away by the local suction system needs to be removed into the atmosphere after dust removal and purification. Common dust collectors include mechanical dust collectors, scrubbers, fabric filters, and electrostatic precipitators. Each type has many different types. Can choose according to the situation.
Fourth, the main dust management work
In order to prevent smoke and dust from harming, in addition to technical measures, management should also be strengthened. The main contents include: keeping the operating environment clean, keeping the dustproof equipment intact, constantly checking the dustproof effect, and performing dust education and training.
Practice has proved that in the production environment where soot is produced, even if dust prevention measures are taken, some smoke and dust will inevitably be scattered. As time goes by, dust and dust will adhere to windows, walls, mechanical equipment surfaces and lighting fixtures. The deposited fumes should be regularly cleaned. Cleaning dust can be performed with wet mops, vacuum cleaners, blow-and-sweep vehicles and other tools and equipment.
As with production equipment, dust-proof equipment must also be carefully maintained, and overhauled to ensure that it can always play a good role. A checklist should be made to list the places that must be checked. At regular intervals, check for any abnormalities. When there is an abnormality, the cause should be investigated, necessary repairs, replacements and replenishments should be made and records made.
The effect of dust prevention should be monitored through technical measurements. The content of the measurement is mainly the smoke concentration of the operating environment and the technical performance of various dustproof devices. This determination should be carried out frequently and problems should be solved in time.
To do dust prevention work, employees should also be educated and trained in dust prevention. The contents should generally include: the hazards of smoke, related regulations, dust prevention methods, the use and maintenance of dust-proof equipment, and the management of the operating environment. In addition, special training and training on smoke control technology and smoke detection methods should also be conducted for technical personnel engaged in dust prevention work.
In recent years, a variety of new welding edge processing technologies have emerged at home and abroad, proving that people still realize the impact of the edging environment. These new processes include edge milling, cleaning, and automatic high-frequency welding. The edge milling process eliminates noise and dust. It is a transitional process that is more adaptable to a typical small-scale barrel making plant and is relatively simple and feasible. Although the cleaning process also eliminates noise and dust, it is often accompanied by toxic and harmful gases due to the use of hydrochloric acid, etc., to corrode the oxides and grease stains on the welding edge, as well as the presence of cleaning waste liquids. It cannot be promoted. Only automatic high-frequency welding process due to its advanced welder characteristics, welding edge generally does not require strict treatment can be welded, remove the processing process, thereby reducing the labor intensity, reducing production costs, environmental pollution has also been improved. This is the replacement process for steel drum welding.
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