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What is the error range for calculating the filtering area of a screen changer?

Differences Between Theoretical Calculations and Actual Situations

The calculation of the filtering area of a screen changer is based on theoretical models and some empirical parameters. However, in practical applications, due to various factors, there may be a certain degree of error between the calculated results and actual requirements.

Firstly, when calculating the filtration rate, the parameters used are only approximate ranges. For different batches of recycled plastics, their viscosity may vary due to factors such as the source of the recycled plastic and its processing history. Even for the same type of recycled plastic, its actual viscosity may fluctuate within a certain range, leading to discrepancies between the filtration rate and the theoretical value.

Factors Influencing the Error Range:

Plastic Characteristics:

The inhomogeneity of recycled plastics is a significant factor. For example, recycled plastics may contain a mixture of different types of plastic components, additives, and impurities. The uneven distribution of these components can lead to changes in the rheological properties of the plastic melt during the filtration process, causing deviations in the actual filtration rate from the theoretically calculated value.

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The thermosensitivity of plastics also affects the error range. If the plastic temperature is not properly controlled during the extrusion process, the viscosity of the melt will change. For thermosensitive plastics, temperature changes may result in significant viscosity variations, altering the filtration rate. Generally, this factor may lead to an error range of approximately ±10% to ±30%.

Equipment Factors:

The manufacturing accuracy and internal structural design of the screen changer itself affect the filtration effect. For instance, the installation flatness of the filter screen, the degree of fit between the filter screen and the internal channels of the screen changer, etc., all influence the flow of the plastic melt on the filter screen. If the filter screen is not installed flatly, the filtration rate in some areas may increase, while other areas may become clogged. In such cases, the error range may reach ±15% to ±25%.

Fluctuations in parameters such as the screw speed and pressure of the extruder also impact the actual demand for filtration area.Unstable screw speed can lead to variations in the flow rate of the plastic melt, causing discrepancies between the actual filtration area demand and the theoretically calculated value. Typically, such fluctuations may result in an error range of approximately ±5% to ±15%.

Operational Factors:

The proficiency of operators in handling the equipment and their level of control over process parameters also affect the error range. For example, during the screen change process, if the operation takes too long, causing changes in the residence time of the plastic melt within the screen changer, it may alter the properties of the plastic melt and, consequently, affect the filtration effect. Such human factors may lead to an error range of approximately ±5% to ±10%.

hydraulic extrusion screen changer

The cleaning and replacement cycle of the filter screen also influence the error. If the filter screen is not replaced according to the optimal cycle, excessive accumulation of impurities on the screen will reduce the filtration area and decrease the actual filtration rate, thereby increasing the error range, which may reach ±10% to ±20%.

Comprehensive Estimation of the Error Range:

Considering the combined effects of all the above factors, under normal circumstances, the error range for the calculation of the filtering area of a screen changer may be approximately ±10% to ±30%.

To minimize errors in practical applications, it is necessary to conduct a detailed analysis of the characteristics of the recycled plastics, precisely control the equipment parameters, and strictly adhere to operating procedures. Additionally, based on actual production conditions, appropriate adjustments and optimizations can be made to the calculated filtration area.

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