废旧线缆资源化破碎设备研究
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摘要
废旧电子产品的资源化是当今环保领域的热点,而废旧线缆的资源化是一个重要课题。废旧线缆中富含铜、铁、塑料等宝贵资源,废旧铜冶炼能耗仅为矿石炼铜的1/8,甚至可直接加工成材。所以提高废旧线缆回收技术进行绿色拆解具有现实意义。
本文针对废旧线缆资源化设备存在的问题:价格昂贵、功耗大、铜损大、刀具磨损严重等进行了研究。
为了给设备研制提供基础数据,我们把一系列试验方法创新性的引入到废旧线缆破碎领域:①线缆结合面力学实验,对PE、PVC、橡胶三种不同外皮的单线和绞线进行了拉伸实验,所做试样中拉力阈值FA在1.59-60N间,脱出功EA0.06-0.53N.m之间;②线缆辊压破碎实验;③线缆超声分离实验。通过超声分离实验、辊压破碎实验,结果发现线缆的破碎难易程度受一下三个条件影响:线缆的直径、线缆的长度、和线缆的材料。线缆直径越大则越容易破碎;线缆长度越短则越容易破碎;线缆外皮越脆则越容易破碎;在实验上基础上提出了一种新型的废旧线缆机械破碎分选工艺,流程为送料装置——剪切——振动筛分——辊压——静电分选。
首先进行线缆破碎理论研究,运用ANSYS 10.0对剪切单元进行了有限元仿真。仿真发现:剪切过程中,应力主要集中在上剪刃容易发生应力集中,出现崩刃现象;剪切过程中上剪刃的左端呈拉应力,右面成压应力,应力最大点的位置随着剪切过程的进行而出现变化。此外进行了剪切单元设备、辊压单元设备、输送机设备的设计。
通过物料粒度测定实验、物料脱出率实验和物料破碎形貌分析发现:在剪切单元,φ2.5绞线的加权算术平均尺寸ds1=3.75;φ0.95单线加权算术平均尺寸ds2=4.53,φ2.5绞线脱出率63.77%,而φ0.95单线的脱出率2.44%;经辊压单元作用后,φ2.5绞线脱出率78.1%,φ0.95单线的脱出率59.7%;形貌分析发现,经剪切铜和塑料分离的主要形式是脱落,极少量是压裂和撕碎,经辊压后,脱落所占比例变小,压裂与撕碎开始占很大比例,物料断面整齐,长度均匀无线段相互缠绕现象。由数据来看,设备满足了设计要求,效果良好。
The resource utilization of E-waste is a hot spot in environmental protection field presently, the resource utilization of waste cable is an important subject in which. Most of the waste cable are waste cable and wire(about 2/3), in which there are copper, iron, rubber and other precious resource. The energy consumption of waste copper is 1/8 of the smelting copper from ore, which even could be used to fabricate profile. So the improving of recycling technology of waste cable is useful. We found the problem are: high price, high loss of power, high loss of copper, serious wear of cutter .etc.
According to equipment problem high price, high loss of power, high loss of copper, serious wear of cutter and so on,we study on how to solve that.
To get more knowledge about composition plane of copper and plastics and be easy to design the equipment, the tensile testing were done to single wire and stranded wire whose outer bark are PE, PVC and rubber. We found that tension value FA is betwwen1.59N and 60N, emergence work EA is betwwen0.06N.m and 0.53N.m.A series of crushing experiment were done in this article including ultrasonic crushing, rolling crushing etc. We found that there were three factors affecting the crushing of waste wire: cable’s diameter, the smaller the more difficulty to crush; length of cable, the longer the more difficulty to crush; cable’s material, the more fragile the easier to crush. Basing on the experiment of tensile testing and crushing experiment, a mechanical crushing and separation process is given. According to the process, the equipment of shearing, rolling and transportation were designed.
Using ANSYS 10.0 to simulate the shearing , find that: the stress is concentrated on up-cutter in shearing ;in the process of shearing, the left hand of the cutter is tensile stress, right hand is compressive stress, and the stress’s peak is changing with shearing.
By means of measurement of grain size granulometry , prolapse rate experiment, Morphology Analysis, find that: after shearing,φ2.5 stranded wire’s ds1=3.75mm,φ0.95 single wire’s ds2=4.53,φ2.5 stranded wire’s prolapse rate is 63.77%,φ0.95 single wire’s prolapse rate is 2.44%; after rolling,φ2.5 stranded wire’s prolapse rate is 78.1%;φ0.95 single wire’s prolapse rate is 59.7%; with morphology Analysis, find that after shearing the separation of copper and outer bark is mainly shedding, fracturing and grinding are a small part, after rolling the separations of copper and outer bark are mainly fracturing and grinding, shedding is a small part. The cable’s cross section is tidiness, there is not mutual winding between the cables. From the data, we get that the designs satisfy the requirement.
本文针对废旧线缆资源化设备存在的问题:价格昂贵、功耗大、铜损大、刀具磨损严重等进行了研究。
为了给设备研制提供基础数据,我们把一系列试验方法创新性的引入到废旧线缆破碎领域:①线缆结合面力学实验,对PE、PVC、橡胶三种不同外皮的单线和绞线进行了拉伸实验,所做试样中拉力阈值FA在1.59-60N间,脱出功EA0.06-0.53N.m之间;②线缆辊压破碎实验;③线缆超声分离实验。通过超声分离实验、辊压破碎实验,结果发现线缆的破碎难易程度受一下三个条件影响:线缆的直径、线缆的长度、和线缆的材料。线缆直径越大则越容易破碎;线缆长度越短则越容易破碎;线缆外皮越脆则越容易破碎;在实验上基础上提出了一种新型的废旧线缆机械破碎分选工艺,流程为送料装置——剪切——振动筛分——辊压——静电分选。
首先进行线缆破碎理论研究,运用ANSYS 10.0对剪切单元进行了有限元仿真。仿真发现:剪切过程中,应力主要集中在上剪刃容易发生应力集中,出现崩刃现象;剪切过程中上剪刃的左端呈拉应力,右面成压应力,应力最大点的位置随着剪切过程的进行而出现变化。此外进行了剪切单元设备、辊压单元设备、输送机设备的设计。
通过物料粒度测定实验、物料脱出率实验和物料破碎形貌分析发现:在剪切单元,φ2.5绞线的加权算术平均尺寸ds1=3.75;φ0.95单线加权算术平均尺寸ds2=4.53,φ2.5绞线脱出率63.77%,而φ0.95单线的脱出率2.44%;经辊压单元作用后,φ2.5绞线脱出率78.1%,φ0.95单线的脱出率59.7%;形貌分析发现,经剪切铜和塑料分离的主要形式是脱落,极少量是压裂和撕碎,经辊压后,脱落所占比例变小,压裂与撕碎开始占很大比例,物料断面整齐,长度均匀无线段相互缠绕现象。由数据来看,设备满足了设计要求,效果良好。
The resource utilization of E-waste is a hot spot in environmental protection field presently, the resource utilization of waste cable is an important subject in which. Most of the waste cable are waste cable and wire(about 2/3), in which there are copper, iron, rubber and other precious resource. The energy consumption of waste copper is 1/8 of the smelting copper from ore, which even could be used to fabricate profile. So the improving of recycling technology of waste cable is useful. We found the problem are: high price, high loss of power, high loss of copper, serious wear of cutter .etc.
According to equipment problem high price, high loss of power, high loss of copper, serious wear of cutter and so on,we study on how to solve that.
To get more knowledge about composition plane of copper and plastics and be easy to design the equipment, the tensile testing were done to single wire and stranded wire whose outer bark are PE, PVC and rubber. We found that tension value FA is betwwen1.59N and 60N, emergence work EA is betwwen0.06N.m and 0.53N.m.A series of crushing experiment were done in this article including ultrasonic crushing, rolling crushing etc. We found that there were three factors affecting the crushing of waste wire: cable’s diameter, the smaller the more difficulty to crush; length of cable, the longer the more difficulty to crush; cable’s material, the more fragile the easier to crush. Basing on the experiment of tensile testing and crushing experiment, a mechanical crushing and separation process is given. According to the process, the equipment of shearing, rolling and transportation were designed.
Using ANSYS 10.0 to simulate the shearing , find that: the stress is concentrated on up-cutter in shearing ;in the process of shearing, the left hand of the cutter is tensile stress, right hand is compressive stress, and the stress’s peak is changing with shearing.
By means of measurement of grain size granulometry , prolapse rate experiment, Morphology Analysis, find that: after shearing,φ2.5 stranded wire’s ds1=3.75mm,φ0.95 single wire’s ds2=4.53,φ2.5 stranded wire’s prolapse rate is 63.77%,φ0.95 single wire’s prolapse rate is 2.44%; after rolling,φ2.5 stranded wire’s prolapse rate is 78.1%;φ0.95 single wire’s prolapse rate is 59.7%; with morphology Analysis, find that after shearing the separation of copper and outer bark is mainly shedding, fracturing and grinding are a small part, after rolling the separations of copper and outer bark are mainly fracturing and grinding, shedding is a small part. The cable’s cross section is tidiness, there is not mutual winding between the cables. From the data, we get that the designs satisfy the requirement.
引文
[1] Harrad S, Mao H. Atmospheric PCBs and organochlorine pesticides in Birmingham,UK: concentration,sources,temporal and seasonal trends. Atmos Environ, 2004;38:1437–45.
[2] Warczok, J., Pers, A. & Smieszek, Z. Processing of cable scrap in Poland. n: Proceedings of the Recycling of Metalliferous Materials Conference, Birmingham, London, UK: Institution of Mining and Metallurgy, , 1990: p. pp. 283–289
[3] UNEP. E-waste: the hidden side of IT equipment's manufacturing and use. Early Warnings on Emerging Environmental Threats No.5. United Nations Environment Programme; 2005.
[4]邱焕玲,论发展循环经济的理论与实践.商场现代化, 2009年(04期): p. 270.
[5]宋德永,潘.王.杨,用循环经济的理念促进工业废物资源化[J].环境与可持续发展, 2009(01期).
[6]北方最大再生资源及有色金属集散地—天津子牙环保产业园,金羊网,http://www.ycwb.com/myjjb/2008-08/12/content_1951639.htm.
[7]郭学益,宋瑜,王勇,我国铜资源物质流分析研究[M],自然资源学报,2008年7月第4期。
[8] FUDao. About1 /3 of copper consumption in China comes from waste copper[J],News of China Nonferrous Metals, 2005-07-12(7).
[9]王伟,高兴保,生活垃圾焚烧飞灰中的二噁英分布及指示异构体的识别,环境科学[J], 2007年02期
[10]废旧电线电缆自动剥皮分离机,技术与市场[J], 2000年11期。
[11]刘建,罗晓曙,陈赤,梁俊英,PLC在自动剥线机中的应用[J],现代电子技术, 2008年第3期总266期,p128.
[12]梁焱,郭有仪,郁永章,橡胶低温破碎条件的突变分析[J],低温工程, 2001(3): 34 ~43
[13]何永峰,刘玉强胶粉生产及其应用废旧橡胶资源化新技术[M],北京:中国石化出版社,2001 72~75
[14]庄伟强固体废弃物处理与利用[M]北京:化学工业出版社, 2001 5~33
[15]蒋鼎琮;阎瑞河;裴国良;废旧电线电缆回收处理技术[J],有色设备, 1997年04期。
[16] Koehnlechner, R. Copper separation from cable scrap. Wire Industry, 1994(61): p. 342–343.
[17] Mankosa, M.J.C., R. M. Processing of chopped wire waste material using the ?oatex density separator. In: Queneau, P. B. & Peterson, R. D. (eds.) 3rd International Symposium on Recycling of Metals and Engineered Materials. Warrendale, PA, USA: Minerals, Metals and Materials Society, 1995: p. pp. 111–120.
[18]杨惠芬.固体废物处理技术及工程应用[M].北京:机械工业出版社, 2003。
[19] Kopp, Wilhelm (Pfrungen, DE) ,Process for dividing up and recovering the individual materials from old cablesPatent,USA, US4964577, 07/376670, 10/23/1990
[20]任德树.粉碎筛分原理与设备[M].北京:冶金工业出版社,1984.34-47; 472-482.
[21]许凤和,高分子材料力学实验[M].北京:科学出版社,1987. 76
[22]张鹏,辊压造粒机压辊分离力的近似计算[J],中国井矿盐,第33卷,2003年9月第5期,p37-38
[23]张宝珍等,剪切机械安全技术[M.].北京:劳动人事出版社,1989年2月北京第一版,19-30.
[24]师汉民.金属切削理论及应用新探[M].武汉:华中科技大学出版社,2003
[25]曾正明.机械工程材料手册.金属材料(第六版)[M].北京:机械工业出版社,2003
[26]中华人们共和国冶金工业部,YB 4070.1-92,金属剪切刀片技术条件剪板机和剪断机刀片,北京,1992年3月9日。
[27] ANSYS Release10.0 Documentation
[28]黄志刚,柯映林,王立涛.金属切削加工有限元模拟的相关技术研究[J].中国机械工程,2003,14(10):846-849
[29]刘晓刚,剪切机刀片在剪切过程中刀刃部分应力分布的ANSYS分析[J],桂林航天工业高等专科学校学报,2002年第3期(总第27期)
[30]柴文福,国内外砻谷机结构的探讨[J],粮食与饲料工业,2000年第9期。
[31]顾尧臣,差动对辊机基本理论与高速磨粉机和变频胶辊砻谷机的研制[J],粮食与饲料工业,2003年第12期,p14
[32]罗园山,胶辊砻谷机喂料机构的改进[J],粮食加工,2006年第2期。
[33]张长森,粉体技术及设备[M],上海:华东理工大学出版社,2007年1月。
[34]刘志超、武良臣等,物料破碎设备设计理论及应用[M]。江苏徐州:中国矿业大学出版社,2006年9月.
[2] Warczok, J., Pers, A. & Smieszek, Z. Processing of cable scrap in Poland. n: Proceedings of the Recycling of Metalliferous Materials Conference, Birmingham, London, UK: Institution of Mining and Metallurgy, , 1990: p. pp. 283–289
[3] UNEP. E-waste: the hidden side of IT equipment's manufacturing and use. Early Warnings on Emerging Environmental Threats No.5. United Nations Environment Programme; 2005.
[4]邱焕玲,论发展循环经济的理论与实践.商场现代化, 2009年(04期): p. 270.
[5]宋德永,潘.王.杨,用循环经济的理念促进工业废物资源化[J].环境与可持续发展, 2009(01期).
[6]北方最大再生资源及有色金属集散地—天津子牙环保产业园,金羊网,http://www.ycwb.com/myjjb/2008-08/12/content_1951639.htm.
[7]郭学益,宋瑜,王勇,我国铜资源物质流分析研究[M],自然资源学报,2008年7月第4期。
[8] FUDao. About1 /3 of copper consumption in China comes from waste copper[J],News of China Nonferrous Metals, 2005-07-12(7).
[9]王伟,高兴保,生活垃圾焚烧飞灰中的二噁英分布及指示异构体的识别,环境科学[J], 2007年02期
[10]废旧电线电缆自动剥皮分离机,技术与市场[J], 2000年11期。
[11]刘建,罗晓曙,陈赤,梁俊英,PLC在自动剥线机中的应用[J],现代电子技术, 2008年第3期总266期,p128.
[12]梁焱,郭有仪,郁永章,橡胶低温破碎条件的突变分析[J],低温工程, 2001(3): 34 ~43
[13]何永峰,刘玉强胶粉生产及其应用废旧橡胶资源化新技术[M],北京:中国石化出版社,2001 72~75
[14]庄伟强固体废弃物处理与利用[M]北京:化学工业出版社, 2001 5~33
[15]蒋鼎琮;阎瑞河;裴国良;废旧电线电缆回收处理技术[J],有色设备, 1997年04期。
[16] Koehnlechner, R. Copper separation from cable scrap. Wire Industry, 1994(61): p. 342–343.
[17] Mankosa, M.J.C., R. M. Processing of chopped wire waste material using the ?oatex density separator. In: Queneau, P. B. & Peterson, R. D. (eds.) 3rd International Symposium on Recycling of Metals and Engineered Materials. Warrendale, PA, USA: Minerals, Metals and Materials Society, 1995: p. pp. 111–120.
[18]杨惠芬.固体废物处理技术及工程应用[M].北京:机械工业出版社, 2003。
[19] Kopp, Wilhelm (Pfrungen, DE) ,Process for dividing up and recovering the individual materials from old cablesPatent,USA, US4964577, 07/376670, 10/23/1990
[20]任德树.粉碎筛分原理与设备[M].北京:冶金工业出版社,1984.34-47; 472-482.
[21]许凤和,高分子材料力学实验[M].北京:科学出版社,1987. 76
[22]张鹏,辊压造粒机压辊分离力的近似计算[J],中国井矿盐,第33卷,2003年9月第5期,p37-38
[23]张宝珍等,剪切机械安全技术[M.].北京:劳动人事出版社,1989年2月北京第一版,19-30.
[24]师汉民.金属切削理论及应用新探[M].武汉:华中科技大学出版社,2003
[25]曾正明.机械工程材料手册.金属材料(第六版)[M].北京:机械工业出版社,2003
[26]中华人们共和国冶金工业部,YB 4070.1-92,金属剪切刀片技术条件剪板机和剪断机刀片,北京,1992年3月9日。
[27] ANSYS Release10.0 Documentation
[28]黄志刚,柯映林,王立涛.金属切削加工有限元模拟的相关技术研究[J].中国机械工程,2003,14(10):846-849
[29]刘晓刚,剪切机刀片在剪切过程中刀刃部分应力分布的ANSYS分析[J],桂林航天工业高等专科学校学报,2002年第3期(总第27期)
[30]柴文福,国内外砻谷机结构的探讨[J],粮食与饲料工业,2000年第9期。
[31]顾尧臣,差动对辊机基本理论与高速磨粉机和变频胶辊砻谷机的研制[J],粮食与饲料工业,2003年第12期,p14
[32]罗园山,胶辊砻谷机喂料机构的改进[J],粮食加工,2006年第2期。
[33]张长森,粉体技术及设备[M],上海:华东理工大学出版社,2007年1月。
[34]刘志超、武良臣等,物料破碎设备设计理论及应用[M]。江苏徐州:中国矿业大学出版社,2006年9月.