I. Material Adhesion and Coking
When highly viscous materials come into contact with the high-temperature heating discs, their surface rapidly dehydrates and carbonizes, forming a hard shell that adheres to the disc surface or the inner wall of the cylinder. This is usually caused by excessively high initial heating disc temperature, excessively large gap between the rake blades and the disc surface (>0.5mm) leading to incomplete scraping, or incorrect start-up sequence (heating before starting the rake blades), causing static material to stick due to heat. Adhesion not only reduces the effective heat transfer area but can also block the discharge channel, leading to operational interruptions.
II. Significantly Reduced Heat Transfer Efficiency
When the material adheres to the heating disc surface, forming a heat insulation layer, heat cannot be effectively conducted to the interior of the material, resulting in slower drying speeds and longer drying cycles. Furthermore, excessively thick or unevenly distributed material layers, and insufficient agitation, can also cause uneven heating, further affecting the overall drying effect, ultimately resulting in excessive final moisture content in the material.
III. Unsmooth Discharge and Blockage
Due to the poor flowability of viscous materials, they easily accumulate in the discharge area, causing poor conveying. Uneven drying, with some areas becoming too dry and clumping, and others becoming too wet and sticky, can lead to intermittent discharge or even complete blockage. Improper adjustment or wear and deformation of the discharge weir plate can also exacerbate this problem.
IV. Abnormal Wear of Rake Blades and Transmission System
Sticky materials significantly increase the running resistance of the rake blades, which can easily lead to deformation and breakage of the blades over time, causing excessive load on the main shaft and abnormal noise. Impurities or lumps in the material can also cause mechanical jamming. Insufficient lubrication or seal failure allows dust to enter the bearings, accelerating component wear.
V. Frequent Downtime and Increased Maintenance Costs
Due to the lack of self-cleaning structures and online cleaning systems, processing sticky materials often relies on manual periodic shutdowns for scraping, which is time-consuming and labor-intensive. Aging and leaking seals, unstable vacuum levels, and other problems also require frequent maintenance, leading to decreased equipment utilization and significantly increased maintenance costs.
