How to replace banana screen mesh / panel

Replacing a banana screen mesh or panel is a common maintenance task for these types of vibratory screens, which are widely used in industries like mining, aggregates, and coal processing. The exact steps can vary slightly depending on the specific design of your banana screen, but here’s a general guide.

How to Replace Banana Screen Mesh / Panel

Double banana sieve

Safety First:

Disconnect Power: Always ensure the machine’s power supply is completely disconnected and locked out/tagged out before beginning any maintenance work. This is crucial to prevent accidental startup.

Allow to Cool: If the machine has been in operation, allow it to cool down to a safe temperature before handling components.

Follow Manufacturer’s Guidelines: Refer to your specific machine’s operation and maintenance manual for detailed instructions and safety precautions.

General Steps to Replace a Banana Screen Mesh/Panel:

Prepare the Area:

Clear any material from the screen surface and surrounding areas.

Ensure you have adequate lighting and space to work safely.

Gather all necessary tools (wrenches, mallets, pry bars, new screen mesh/panels, sealing strips, etc.).

Access the Screen Section:

Depending on the screen design, you may need to open auxiliary devices or access doors that allow access to the screen surface.

Some screens have quick-release latches or clamps that need to be unlatched and removed.

If there are any center hold-down mechanisms or tensioning rails, these will need to be loosened or removed.

Remove the Worn Screen/Panel:

Carefully remove any sealant strips around the edges of the screen.

Lift and remove the damaged or worn screen mesh/panel from the screen deck.

Inspect and remove any residual debris from the support angles, center hold-down mechanisms, end supports, and seals.

Inspect and Prepare the Support Structure:

Check the support beams and wear liners under the screen panels for any looseness, wear, or damage. Replace them if necessary.

Clean the screen grid and any bonding surfaces. If using glue for certain screen types, lightly sand the bonding surface for better adhesion.

If replacing crown rubber/gasket-type elements, seals, or end supports, do so now.

Apply a lubricant to every support angle if recommended by the manufacturer.

Single layer horizontal sieve

Install the New Screen Mesh/Panel:

Positioning: Carefully position the new screen mesh or panel onto the screen deck. Ensure it is centered and aligned correctly with the support structure.

Tensioning (for woven wire mesh):

For proper tensioning, ensure there’s enough give (e.g., ¾”) between the outside of the hook and the side plates.

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What are the maintenance tips for linear vibrating screen

Maintaining a linear vibrating screen is crucial for its optimal performance, longevity, and reliability. Regular maintenance helps prevent breakdowns, reduces downtime, and extends the lifespan of the equipment.

Regular, scheduled maintenance is the key to longevity. Here’s a typical schedule you can adapt to your specific operating conditions (e.g., increase frequency for highly abrasive materials or 24/7 operation).

Linear Vibrating Screen Maintenance

Double banana sieve

I. Regular Inspections (Daily, Weekly, Monthly, Annually):

Daily:

Perform a visual inspection of the machine’s environment and the machine itself for any signs of material buildup, caking, or loose components.

Inspect the mounting system and safety guards, ensuring they are secure and free from damage.

Visually inspect the screen media (mesh, panels) for cleanliness, proper tension, and any signs of wear, tears, or damage.

Check drive bearings for proper lubrication and intact grease lines, noting any excess lubricant leakage.

Listen for any abnormal noises during operation.

Weekly:

Inspect the central lubrication system (if equipped) for blocked grease lines or leaks.

Check bearing temperature after the machine has been running for at least four hours using an infrared thermometer.

Inspect the vibrator and all bolts for looseness.

Check rubber springs for damage.

Monthly:

Inspect drive V-belts and drive systems for wear, tension, and leaks. Replace worn, damaged, or missing V-belts as a set.

Conduct a thorough inspection of all bolted connections, tightening loose bolts and replacing any missing hardware.

Inspect the screen frame structure and weld seams for cracks. If cracks are found, clean the surface, drill holes at the ends to prevent extension, shovel the groove, preheat, and repair weld (ensure penetration and grind flat after welding). Add reinforcement plates if necessary, avoiding holes or welding accessories on the screen frame to prevent stress concentration.

Annually:

Overhaul the vibrator: disassemble completely for cleaning. Replace rolling bearings if pitted or broken. When reassembling, ensure the eccentric block positions of the vibrator maintain the same phase.

Consider scheduling a professional evaluation (e.g., PROcheck service).

II. Key Maintenance Practices:

Single layer horizontal sieve

Lubrication:

Proper lubrication is essential for smooth operation. Regularly lubricate bearings, drive mechanisms, and other moving parts according to the manufacturer’s recommendations.

Use the appropriate lubricant (e.g., 2# lithium-based grease in winter, 3# lithium-based grease in summer) and apply in recommended quantities. Avoid overfilling.

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How to do with blistering/decolorization of printed aluminum sheets?

Printed aluminum sheets are widely used across industries for their durability, aesthetic appeal, and corrosion resistance. However, issues such as blistering and discoloration can compromise their appearance and performance, leading to product rejection, increased costs, and customer dissatisfaction. These defects often stem from problems in surface treatment, ink formulation, or the printing and baking process. Blistering and decolorization of printed aluminum sheets can be frustrating issues. Here’s a breakdown of how to address them.

How to do with blistering/decolorization of printed aluminum sheets

Printed aluminum sheets

Understanding the Causes

Several factors can lead to blistering and decolorization:

Moisture: Trapped moisture, either from the environment or the printing process, can cause blistering, especially during heat treatment. This moisture can react with the aluminum at high temperatures, forming hydrogen gas that creates blisters.

Contamination: Residues like salts, acids, or cleaning agents left on the aluminum surface before printing can interfere with the adhesion of the ink or react during heating, leading to blistering or discoloration.

Incompatible Inks/Coatings: Using inks or coatings that are not compatible with aluminum or the printing process can result in poor adhesion, leading to blistering or peeling.

Improper Application: Applying inks or coatings too thickly or unevenly can trap solvents, leading to blistering as the solvents try to escape during drying or heating.

Oxidation: While aluminum naturally forms a protective oxide layer, a thick or uneven layer can affect ink adhesion and potentially lead to discoloration.

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What is the production process of coated aluminum sheet?

The production of coated aluminum sheets involves a precise, multi-step process designed to enhance the surface properties of aluminum for decorative, functional, and protective purposes. The process begins with high-quality aluminum coils, which are first cleaned and chemically pre-treated to improve coating adhesion.

Coated Aluminum Sheet Production Process

coated aluminum sheets

Uncoiling & Splicing:

Uncoiling: Large coils of bare aluminum (mill finish) are loaded onto an uncoiler.

Splicing (Optional but common for continuous lines): The end of one coil is often stitched or welded to the beginning of the next coil to allow for continuous operation without stopping the line. An accumulator loop provides slack during this process.

Cleaning & Pre-treatment (Crucial for Adhesion & Corrosion Resistance):

Degreasing/Cleaning: The aluminum strip passes through a series of cleaning tanks or spray zones. This typically involves alkaline cleaners to remove oils, grease, dirt, and other surface contaminants.

Rinsing: The strip is thoroughly rinsed with water to remove any residual cleaning solution.

Deoxidizing/Etching (Optional but common): An acidic solution may be used to remove the natural oxide layer and lightly etch the surface, creating a better micro-profile for adhesion. This is followed by another rinse.

Conversion Coating (Chemical Pre-treatment): This is a critical step. The aluminum strip is treated with a chemical solution (historically chromate-based, but increasingly non-chromate alternatives like titanium or zirconium-based are used for environmental reasons). This process forms a thin, inert conversion layer on the aluminum surface that:

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What are the thicknesses of aluminum sheets and how to choose?

Aluminum sheets come in a wide range of thicknesses, catering to diverse applications. The way thickness is specified can vary, but typically it’s in inches (imperial) or millimeters (metric).

Understanding Aluminum Thickness Terminology:

Foil: Extremely thin aluminum, typically less than 0.0079 inches (0.2 mm). Think kitchen foil.

Sheet: Generally defined as material between 0.0079 inches (0.2 mm) and 0.249 inches (6.3 mm). This is the most common form for many fabrication projects.

Plate: Material that is 0.250 inches (6.35 mm) or thicker. Used for more structural or heavy-duty applications.

Common Aluminum Sheet Thicknesses:

Aluminum sheets

It’s common to see thicknesses specified in decimals of an inch or in millimeters. While there’s a “gauge” system for sheet metal, it’s less universally standardized for aluminum than for steel, and can be confusing. It’s always best to specify the actual thickness in inches or mm.

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How to clean printed aluminum sheets

Printed aluminum sheets are widely used for decorative panels, signage, appliance surfaces, and architectural finishes due to their durability, vibrant appearance, and resistance to corrosion. However, to maintain their aesthetic appeal and extend their lifespan, proper cleaning and maintenance are essential.Cleaning printed aluminum sheets requires a gentle approach to protect the print while effectively removing dirt and grime.

How to clean printed aluminum sheets

Printed aluminum sheets

General Cleaning Principles:

Always use the mildest method first: Start with the gentlest cleaning agents and only move to stronger ones if necessary.

Avoid abrasive materials: Never use steel wool, abrasive sponges, rough cloths, or harsh brushes, as these can scratch the printed surface. Stick to soft cloths, microfiber towels, or soft-bristled brushes.

Test in an inconspicuous area: Before applying any cleaner to the entire sheet, test it on a small, hidden spot to ensure it doesn’t cause damage or discoloration.

Work gently: Don’t scrub aggressively. Use light, circular motions.

Rinse thoroughly: After cleaning, rinse the surface with clean water to remove any cleaning solution residue, which can cause streaks or damage over time.

Dry completely: Dry the printed aluminum sheet immediately and thoroughly with a clean, soft cloth to prevent water spots and streaks.

Recommended Cleaning Solutions and Methods:

Dusting:

For light dust and loose debris, simply use a soft, dry microfiber cloth or a feather duster to gently wipe the surface. This prevents dust from scratching the print if you proceed with wet cleaning.

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Which graphite sheet is best for sealing steam

In high-temperature and high-pressure environments such as steam systems, the choice of sealing material is crucial. Graphite sheets are widely recognized for their excellent thermal stability, chemical resistance, and sealing performance. However, not all graphite sheets are created equal. For sealing steam, flexible graphite sheets, particularly those reinforced with metal inserts, are generally considered the best option.

Which graphite sheet is best for sealing steam

graphite sheet

Why Flexible Graphite for Steam?

High Temperature Resistance: Flexible graphite can withstand extremely high temperatures, often up to 550℃(1022℉) in air and up to 700℃ (1292℉) in steam or inert environments. This is crucial for steam applications which involve high temperatures and pressures.

Excellent Sealability: Graphite is highly compressible and conformable, allowing it to fill microscopic irregularities on flange surfaces and create a tight, leak-proof seal. It also has a low relaxation rate, meaning it maintains its seal over time, even with temperature and pressure fluctuations.

Chemical Resistance: It’s resistant to a wide range of chemicals, including most acids, alkalis, and organic compounds, making it versatile for various industrial applications.

Thermal Stability: Graphite gaskets exhibit excellent thermal stability, meaning they don’t embrittle, change structure, or lose components under high temperatures.

This prevents creep or flow of the gasket.

No Binders/Fillers: Pure flexible graphite sheets are typically made without organic or inorganic binders and fillers, which can degrade at high temperatures and compromise the seal.

Longevity: Due to its inherent properties, flexible graphite offers good long-term sealing performance and resistance to aging, although oxidation can occur at very high temperatures in oxygen-rich environments.

Types of Graphite Sheets Best for Steam:

Reinforced Flexible Graphite: This is often the preferred choice for steam due to the added strength and stability provided by the reinforcement. Common reinforcement materials include:

Stainless Steel Foil (Flat or Perforated): Provides enhanced mechanical strength, pressure resistance, and improved handling. Perforated (tanged) inserts create a strong mechanical bond with the graphite, preventing delamination.

Nickel or other metal inserts: Similar benefits to stainless steel, depending on specific application requirements.

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What is the performance of graphite soft felt?

Graphite soft felt is a flexible, high-temperature insulation material made from carbon or graphite fibers. Its performance is characterized by a unique combination of thermal, chemical, mechanical, and electrical properties.

Graphite Soft Felt Performance

Graphite soft felt

1. Thermal Performance:

High-Temperature Stability: This is its primary advantage. It can withstand extremely high temperatures, typically up to 2500°C (4532°F) and even higher (up to 3000°C) for short durations in inert or vacuum atmospheres. In oxidizing atmospheres, its use is limited to around 400-500°C.

Low Thermal Conductivity: It’s an excellent thermal insulator, especially in vacuum or inert gas environments. Thermal conductivity typically ranges from 0.08 to 0.2 W/m·K at room temperature, and it generally decreases with increasing temperature up to a certain point (around 1500-2000°C) before radiation effects start to dominate and increase apparent conductivity.

Low Specific Heat: It heats up and cools down relatively quickly, which can be advantageous for rapid thermal cycling.

Good Thermal Shock Resistance: Due to its fibrous nature and low coefficient of thermal expansion, it can withstand rapid temperature changes without cracking or degrading.

Low Outgassing (after proper treatment): When properly purified and baked out, it exhibits low outgassing, making it suitable for high-vacuum applications.

2. Chemical Performance:

High Purity: Typically has a high carbon content (often >99%, with some grades >99.9%) and low ash content. This minimizes contamination in high-temperature processes.

Chemical Inertness: Highly resistant to most corrosive chemicals, acids, bases, solvents, and molten metals (except strong oxidizing agents or metals that form carbides at very high temperatures).

Non-Wetting: Generally not wetted by many molten metals, which can be beneficial in metallurgical applications.

3. Mechanical Performance:

Flexibility and Conformability: Being “soft,” it can be easily bent, wrapped around complex shapes, or compressed to fit into tight spaces.

Low Density: Typically very lightweight (e.g., 0.08 – 0.2 g/cm³), which reduces the overall weight of insulation systems.

Low Strength: It has low tensile and compressive strength. It’s not a structural material and can be easily torn or damaged if handled improperly.

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More detailed information about the performance of graphite felt can be found by clicking on the following link: https://www.czgraphite.com/a/news/graphite-soft-felt-performance.html

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What is the role of graphite in heat treatment?

Graphite plays a critical role in heat treatment processes due to its exceptional thermal stability, chemical inertness, and excellent heat conductivity. Widely used in high-temperature furnaces, graphite components—such as insulation boards, heating elements, and crucibles—help maintain consistent temperature control and ensure a clean processing environment.

Graphite in Heat Treatment Role

Graphite

Furnace Components & Fixtures:

High-Temperature Stability: Graphite can withstand very high temperatures (sublimes at ~3650°C) without melting, making it ideal for furnace linings, insulation, trays, boats, grids, and fixtures used to hold parts during heat treatment.

Low Thermal Expansion: It has a low coefficient of thermal expansion, meaning it doesn’t change size or shape significantly with temperature changes, preventing distortion of the fixtures or the parts they hold.

Thermal Shock Resistance: Graphite can withstand rapid temperature changes without cracking, which is common in heat treatment cycles.

Machinability: It can be easily machined into complex shapes for custom fixtures.

Heating Elements:

Electrical Conductivity: Graphite is a good electrical conductor, allowing it to be used as a resistance heating element in vacuum furnaces or furnaces with controlled atmospheres. It heats up when an electric current passes through it.

High Emissivity: It radiates heat efficiently, contributing to uniform heating within the furnace.

Susceptors (for Induction Heating):

In induction heating, a non-conductive material might need to be heated. A graphite susceptor can be placed near or around the material. The induction coil heats the graphite susceptor, which then radiates heat to the target material.

Crucibles and Molds:

Chemical Inertness: Graphite is relatively inert and does not react with many molten metals or materials being heat-treated, preventing contamination.

Non-Wetting: Many molten metals do not “wet” graphite, making it easier to remove the treated part or molten material from graphite crucibles or molds.

Thermal Conductivity: Good thermal conductivity allows for even heating and cooling of the contents within a graphite crucible.

Graphite

Protective Atmospheres & Carburizing Agents:

Oxygen Scavenger: In some applications, particularly at very high temperatures in a slightly oxidizing environment, graphite can act as an oxygen scavenger by

reacting with oxygen to form CO or CO2, thus protecting the workpiece from oxidation.

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How to Choose the Right Graphite Ring for High-Temperature Applications

Choosing the right graphite ring for high-temperature applications requires careful consideration of several factors to ensure optimal performance and longevity. Here’s a guide to help you make the best selection.

Graphite Ring Choose

graphite ring

1. Understand the Operating Conditions:

Temperature: Determine the continuous and maximum operating temperatures. Graphite rings can withstand very high temperatures, but their performance can be affected by the presence of oxygen.

Oxidizing Environments (e.g., air): The maximum temperature is typically around 450-500°C (842-932°F). Some sources mention up to 650°C (1202°F), but oxidation becomes more significant at these higher temperatures

Steam Environments: Graphite can handle temperatures up to 650°C (1202°F).

Non-Oxidizing Environments (e.g., vacuum, inert gases): Graphite can withstand exceptionally high temperatures, potentially reaching up to 3000°C (5432°F).

Pressure: Identify the system’s operating pressure. Higher density graphite rings offer greater pressure resistance and can handle pressures exceeding 300 bar (around 4350 psi).

Media: Determine the chemical compatibility requirements. Graphite generally offers excellent resistance to a wide range of media, including hot water, steam, hydrocarbons, chemicals, and solvents, across a broad pH range (0-14). However, it’s not suitable for strong oxidizing agents.

Speed (for dynamic applications): If the ring will be used in rotating equipment, consider the shaft speed. Different graphite grades and ring densities may be recommended for various speed ranges.

Static or Dynamic Application: Rings for static applications (e.g., gaskets in heat exchangers, flanges) and dynamic applications (e.g., sealing in pumps, valves, compressors) might have different design considerations.

2. Consider the Material Properties of Graphite:

Purity: Higher purity graphite (higher carbon content, typically >98%) generally offers better sealing efficiency, corrosion resistance, and oxidation resistance. Nuclear-grade graphite with even higher purity is available for critical applications.

Density: Density affects the ring’s strength, pressure resistance, and sealing capability. Higher density rings (e.g., 1.8 g/cm³) are suitable for higher pressures. Common density ranges are 1.3 to 1.8 g/cm³.

Ash Content: Lower ash content indicates higher purity and can be important for certain sensitive applications.

Sulphur, Chloride, and Fluoride Content: Low levels of these impurities are crucial to minimize corrosion, especially in steam and water environments. Good quality graphite should have sulphur content below 300-500 ppm, and chlorides and fluorides below 50 ppm (industrial grade) or even 20 ppm (nuclear grade).

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More detailed information on how to select the right graphite ring for high temperature applications can be found at: https://www.czgraphite.com/a/news/graphite-ring-choose.html

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