The core operating data of the ultra-high pressure nano homogenizer includes pressure, flow rate, temperature, and the particle size data of the homogenized material can also indirectly reflect whether the equipment is operating abnormally. When making judgments, methods such as comparing standard parameters, observing data stability, and combining equipment failure phenomena can be used, as follows:
Abnormal judgment of pressure data
Comparison of rated pressure to determine deviation: Different models of equipment have clear rated working pressures, such as the GS-120H model with a maximum rated working pressure of 1800 bar and a designed maximum pressure of 2000 bar. If the actual working pressure continues to be lower than the process requirements and cannot be increased through pressure regulation, it may be due to issues such as particle blockage in the inlet one-way valve or leakage of the homogenization valve; If the pressure suddenly rises, it is highly likely that the interaction chamber or high-pressure filter valve is blocked. For example, frequent pressure surges caused by the same batch of materials are mostly due to untreated materials and large particles blocking the chamber. In addition, if the pressure gauge pointer does not return to zero after the shutdown and pressure relief, it is not due to abnormal pressure data, but rather the pressure gauge itself is damaged and needs to be replaced in a timely manner.
Observing the amplitude of pressure fluctuations: Under normal operating conditions, the pressure should remain stable. If the pressure fluctuates frequently and significantly, after excluding the situation of uneven material viscosity, it may be due to the mixing of gas in the high-pressure cylinder, poor sealing of the one-way valve, etc. For example, when the sealing of the feed valve fails, there may be fluctuations in pressure, accompanied by unstable material suction.
Abnormal judgment of traffic data
Verify the standard flow range: The equipment design flow is an important reference, for example, the FB-BASIC-110X-PLUS model has a working flow rate of 3-15L/H. If the actual flow continues to be lower or higher than this range and there is no improvement after adjusting the flow rate parameters, there may be an abnormality. Sliding of the main motor belt and leakage of the plunger seal can slow down the flow rate; When the valve is damaged or the pipeline blockage is not completely resolved, there may be a rare situation of a sudden increase in flow rate.
Pay attention to the matching between flow and pressure: There is a certain linkage between flow and pressure, and under normal circumstances, there will be a reasonable decrease in pressure when flow increases. If the flow rate decreases but the pressure also decreases synchronously, it may be due to insufficient material supply or blockage of the feed pipeline; If the flow rate decreases while the pressure increases, it is highly likely that the discharge end pipeline or homogenization chamber is blocked, which is a typical flow pressure data mismatch anomaly.
Abnormal judgment of temperature data
Compared to the normal operating temperature threshold: The equipment has a specified maximum operating temperature, with most models having a maximum feed temperature of no more than 90 ℃, and some models reaching up to 99 ℃. If the outlet temperature of the material far exceeds this standard, or far exceeds the conventional temperature under the same operating conditions, it is considered an abnormal situation. For example, a malfunction in the cooling circulation pump or failure to open the cooling valve can result in delayed material cooling and a sharp increase in outlet temperature.
Monitoring temperature change rate: During the homogenization process, the temperature may rise slightly and slowly due to material compression and friction. If the temperature rises rapidly in a short period of time, it may be due to blockage of the homogenization chamber causing material retention and increased friction, or equipment cooling system failure. Immediate shutdown and troubleshooting are required to avoid material deterioration or equipment damage.
Abnormal judgment of material particle size related data
The core purpose of homogenization is to refine the particle size of materials, which can indirectly reflect whether the equipment is operating normally. If the particle size of the material measured multiple times under the same process parameters is much larger than the set target value, or the particle size distribution is extremely uneven, it may be due to equipment pressure not meeting the actual working requirements, homogenization chamber wear, etc., leading to a decrease in homogenization effect. For example, when the homogenizer head is damaged, even if parameters such as pressure and flow rate are displayed normally, the particle size of the material cannot meet the standard. This is an abnormal correlation data caused by an implicit equipment fault, which needs to be further confirmed by checking the equipment components.