Spray dryers have become one of the most popular drying systems in the industrial sector today. Changzhou Yidu Drying Equipment Co., Ltd. specializes in the design and production of spray dryers, helping numerous companies solve their drying challenges. Our team has been conducting extensive research on spray dryer technology, and we frequently discuss common issues that arise during operation. While we often share solutions internally, we haven’t always made them widely available. In previous articles, such as “Common Causes and Solutions for Spray Dryers†and “Spray Dryer Leakage Solutions,†we covered some typical problems. Today, we’ll take a closer look at other potential faults and provide effective remedies.
Fault 1: Smoke is emitted from the spray dryer, and an alarm sounds.
Upon inspecting the filter, you may find a large amount of ash, signs of electrical heating damage, and agglomerated materials at the discharge port. The first step is to immediately cut off the power supply and extinguish any fire. This issue typically occurs due to the combustion of the system’s inlet filter. During the drying process, dust particles can accumulate on the filter element. If the temperature inside the heating chamber becomes too high, the paper filter can ignite spontaneously.
Fault 2: The atomizer produces unusual noise.
A squeaking sound may be heard while the nebulizer is running. Upon inspection, the atomizing disc and material distributor appear to be in good condition. However, a crack of approximately 8 mm is found in the rear bearing housing, and there is a 0.5 mm deep wear mark on the inner race of the bearing. A closer examination reveals a blue burning spot.
To address this, the rear bearing housing should be repaired by tapping, and both the front and rear bearings need to be replaced. We conducted no-load and loaded motor tests and observed that the vibration levels didn’t change significantly, suggesting the vibration isn’t caused by the atomizing disc or material distributor. The vibration in the rear bearing housing is greater than in the front, indicating the issue lies with the bearing. When the atomizing disc rotates at high speed, it generates significant centrifugal force. If the bearing has radial clearance, the balls in the non-loaded area can become unbalanced, causing abnormal noise.
To resolve this, a corrugated spring with a thickness of 0.5 mm, outer diameter of 32 mm, and inner diameter of 28 mm is installed on the rear bearing housing. The spring has a preload compression of 1.5 mm, which helps compensate for axial movement of the bearing. When the motor rotor expands due to heat, the inner ring of the bearing also shifts, reducing excessive clearance.
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