Belt Conveyor Transfer Point Dust Control Solution

Problem Statement
1.1. High-Concentration Dust Dispersion
Potassium chloride particles (typically ≤1mm in size, low density) generate dust concentrations of 50–100 mg/m³ during transfer due to drop impact and airflow turbulence, severely endangering worker health.
1.2. Severe Equipment Corrosion & High Maintenance Costs
Corrosive potassium chloride dust accumulates on equipment surfaces, accelerating metal component rusting. Annual maintenance costs reach RMB 400,000, with equipment lifespan reduced to 1–2 years.
1.3. Ineffective Traditional Dust Control
Conventional negative pressure dust collection systems achieve only 30%–40% efficiency while requiring external energy (≥15 kW/h consumption), resulting in high operational costs.
1.4. Reduced Production Efficiency
Material adhesion on belts causes return belt carryback, necessitating frequent downtime for cleaning.
Solution Implementation
Engineered based on aerodynamic principles and material characteristics of potash fertilizer (hygroscopicity, high corrosiveness), this system implements comprehensive retrofitting at transfer points of existing potash fertilizer belt conveyors.
2.1. Potash-specific Sealed Loading Chute
2.1.1. Structure
2.1.1.1. Height Increase: Expanded by 30% to increase capacity and reduce pressure.
2.1.1.2. Dual-layer Side Seals
①First Layer: Dynamic seal fills gaps between side plates and conveyor belts.
②Second Layer: Y-type anti-overflow apron (wear-resistant, high-temperature resistant).
2.1.1.3. Tail Dual-stage Sealing
①Inner Layer: Flame-retardant sponge partition.
②Outer Layer: Rubber sealing plate.
③Effectively prevents dust gas and material overflow from the chute tail.
2.1.2. Function
①Balances internal/external pressure differentials.
②Suppresses induced airflow to reduce dust escape rates.
2.2. Curved Discharge Chute
2.2.1. Design
①DEM-CFD Coupled Simulation Optimization: Enhances flow dynamics through computational modeling.
②UHMW-PE Wear-resistant Liners: Installed on inner walls to reduce material impact forces.
③Induced Airflow Control: Limits horizontal velocity difference between discharged material and receiving belt to ≤5%, minimizing airflow generation.
2.2.2. Function
Prevents Material Blockages: Optimized curvature ensures uninterrupted flow.
Reduces Dust Dispersion: Suppresses dust generation from airflow shear at the outlet.
2.3. Head Chute Dynamic Sealing System
2.3.1. Structure
2.3.1.1. Curved Head Chute Design
①Equipped with flow-guiding liners conforming to potash discharge trajectories.
②Corrosion-resistant dust suppression curtains (Fluorocarbon Rubber) installed between the hood and conveyor belt.
2.3.1.2. Upgraded Cleaning System
Polyurethane cleaners boost material adhesion removal efficiency by 90%.
2.3.2. Function
①Reduces dust generated by material impact.
②Lowers dust concentration at the head section to ≤4 mg/m³.
2.4. Return Flow Pipe & Expansion Zone
2.4.1. Design
2.4.1.1. Pressure Differential-driven Airflow Circulation:
Utilizes pressure differences between the discharge pipe (low-pressure zone) and loading chute (high-pressure zone) to drive dusty airflow recirculation, enabling turbulent coalescence of dust particles.
2.4.1.2. Flexible Damping Curtains in Expansion Zone:
Enhances vortex coalescence and centrifugal sedimentation of dust through flow turbulence optimization.
2.4.2. Function
Improves total dust sedimentation efficiency without external power input.