When a steel plant recently started up its new sludge briquetting line, a series of unexpected issues quickly emerged. In response, Jianjie’s product engineer team was invited to the site to provide professional guidance and help the customer restore stable, controllable operation.
Material Ratio and Feed Control Issues
During the on-site assessment, Jianjie’s engineers found that the plant lacked a standardized raw material ratio. The sludge, dust, and coarse particles were manually loaded, while lime addition relied on visual estimation. Without quantitative control, the mix fluctuated greatly, resulting in unstable briquette quality and lower production efficiency.
Jianjie’s Solution:
Our engineers inspected the blending process, checked mixer parameters, and verified moisture readings. Based on the findings, Jianjie provided targeted recommendations to optimize material proportions and improve feeding consistency.
Jianjie Product Engineers’ On-Site Technical Support
Inaccurate Binder Feeding System
Another key issue was found in the binder feeding system. The discharge valve under the binder hopper required manual operation, and the binder dosage varied from batch to batch. This caused fluctuations in briquette strength and drying performance.
Jianjie’s Solution:
Jianjie’s experts advised the customer to replace the outdated valve with a controllable dosing system, allowing for accurate and consistent binder addition. This seemingly small adjustment plays a critical role in stabilizing the briquetting process and ensuring repeatable results in future production runs.
Mixer Malfunction and Process Interference
The investigation also revealed mechanical issues with the twin-shaft mixer. Due to a failure in the dividing mechanism, both mixers were receiving raw materials simultaneously, which disrupted the intended process sequence and caused uneven mixing.
Jianjie’s Solution:
Jianjie worked closely with the customer’s maintenance team to identify the fault and propose a repair plan, emphasizing that restoring proper mixing control is essential for maintaining product uniformity and achieving predictable briquette strength.
Moisture Control and Furnace Problems
The newly installed moisture analyzer showed inconsistent readings. Some briquettes exhibited little change in moisture before and after drying, while others were overly dry, indicating an issue with the drying furnace.
Although the briquettes reached a dry strength of 1500–1700 N, meeting the plant’s target, the pre-drying water content remained high at about 8%, above the required level of 4%.
Jianjie’s Solution:
Our engineers provided guidance on moisture adjustments and equipment calibration to ensure accurate measurements and reliable furnace performance.
From “Experience-Based” to “Data-Driven” Production
Through this comprehensive on-site service, Jianjie helped the customer transition from experience-based operation to a more data-guided and standardized production mode. The team not only addressed immediate issues but also established a foundation for process stability and quality consistency across future production runs.
By combining advanced binder technology with hands-on technical support, Jianjie delivered a practical and effective solution tailored to the customer’s production conditions. This approach reflects Jianjie’s service goal, identifying root causes, solving problems at their source, and building long-term value through sustainable process optimization.
Common Challenges in Sludge Briquetting Lines
Beyond this particular case, many newly commissioned sludge briquetting lines in steel plants face similar challenges.
Raw Material Variations
- Fluctuating Fe content and moisture levels in sludge
- Presence of oil, chloride, and other impurities affecting briquette strength and drying behavior
- Uneven particle size distribution or excessive fines leading to poor compactness and surface cracking during drying
Operational Issues
- Inconsistent feeding or inadequate mixing during production
- Improper pressure settings reducing briquette uniformity and strength
- Overlapping problems that make stable performance difficult to maintain
That is why Jianjie’s approach goes beyond скоросшиватель formulation, emphasizing a comprehensive understanding of raw material properties, process design, and on-site parameter optimization. This integrated method enables steel plants to achieve stable and high-quality sludge briquetting from commissioning to full-scale production.
Reliable Partner for Sustainable Production
Building on this successful experience, Jianjie continues to support steel plants worldwide with advanced binder solutions and professional technical services, helping customers transform production challenges into long-term stability and efficiency.
Contact our team to learn how we can support your production line.
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