1. Purposes of CZPT Vulcanization Autoclave
Rubber vulcanization is a chemical process at a given force, temperature and time for converting all-natural rubber into much more resilient supplies by the addition of sulfur. These additives modify the polymer by forming cross-links (bridges) in between individual polymer chains. Vulcanized components are considerably less sticky and have outstanding mechanical properties. And vulcanization autoclave is utilized extensively for this chemical method. The major merchandise are galoshes, rubber tubes, cable, rubber roller, rubber ball, etc.In this area, CZPT has been the leader, as we have accrued full vulcanization expertise and technologies for a lot of years.
two. Simple Design Knowledge
two.1 Model and Dimension
- Autoclave product: SN-LHGR2050D
- Successful diameter: 2000mm
- Effective duration: 5000mm
Definition: * Effective diameter is the inner diameter of the autoclave.
* Powerful length is to level to do the real length of the shell.
2.two Creation Potential
- Working circle of autoclave: can be set in accordance to the working method
- Max measurement of pulley: Ø1700X5000mm
2.3 CZPT Energy
- Operating voltage: 415V (AC)±5%, 3 period, 50 Hz
- Management energy: 220VAC/50Hz/24VDC
2.four Water, Air and Steam Offer
- Cooling h2o consumption: ~2mthree/h
- Cooling drinking water force: min.three bar ~ max. 6 bar
- Manage air of manage products: 5 ~ 7bar
- Steam capability: 2t/h
two.five Environmental Conditions
- Max. air temperature: +50ºC
- Min air temperature: -5ºC
- Relative Humidity: <80%
- Altitude: <2000m
three. CZPT Characteristic and Working Procedure
3.1. CZPT Attribute
Autoclaves with direct steam: heating and pressurization are carried out with steam. This heating technique is notably effective and indicated for merchandise of large sizes and weight. The temperature uniformity which normally varies between +/- 2°C,the trade capability, taking place with condensation on colder surfaces, coupled with analyzed installations, let to obtain excellent outcomes.
three.two Working Procedure
three.2.1 CZPT curing recipe
| Item | Temp. setpoint | Soak Time | Temp. step period |
| Segment1 | T1 | t 1-two | t 1 |
| Segment2 | T2 | t three-four | t two |
| Segment3 | T3 | t 5-6 | t 3 |
3.two.two A brief curing recipe instance
four. Gear CZPT Specifics
4.1 Pressure Vessel
CZPT Strain vessel with fast-opening doorway, can be certified to:
- CHINESE STHangCZPTRD, GB150-2011
- AMERICAN STHangCZPTRD ASME SEC VIII DIV.one with ASME Certificate
- EUROPEAN STHangCZPTRD PED ninety seven/23/EC with CE certificate.
four.2 CZPT System
- The closing program of the autoclave is the indented type assisted with a hydraulic program, in buy to swiftly and secured make a entirely airtight closing.
- The total technique is made up of 3 areas: a pair of equipment flange, pushed products and seal ring.
- CZPTally operated door opening and closing. It is controlled by PLC program.
- The seal ring is manufactured of silicon rubber.
- Basic safety pressure sensors have to prevent door opening in circumstance of force (permitted much less than .1 bars).
4.3 Thermal Insulation Program
Interior Insulation and External Insulation
We use ceramic fiber as the insulation substance. The heat transfer coefficient is very low to make the heat loss to a least. The covering board of ceramic fiber is stainless metal. It is corrosion resistant and seems to be good. Inside insulation design and style can get a low strength usage, although external insulation design and style gets a high 1, but a much better temperature uniformity.
- Insulation:External insulation layer
- Insulation content:Ceramic fiber
- External sheet steel: stainless metal,one. mm
- Insulation thickness:50mm
four.4 Internal Coating
- Purpose: Anti-corrosion
- Spraying approach: Aluminum coating
- Thickness:.fifteen-.2mm
four.5 Hot Air Circulating Program
We use modified centrifugal impellers, which can produce huge air movement and higher air strain. And we adopt a dynamic and mechanical sealing design. The dynamic and static ring sealing substance is silicon carbide-graphite.
The design and style of air duct composition is a U sort with movement guiding device, which can make sure the adequacy of very hot air circulation. The forced convection fee inside of the autoclave can attain much more than 90%. By this design, the system can receive a regular and uniform temperature growing fee.
four.5 Internal Rails and Elements
- Rails: 100x75X8mm Angle, stainless steel
- Steam spray pipe:stainless metal
- Pipe joints on autoclave: stainless steel
four.7 Direct Steam Heating and Pressurization
There are two steam distribution pipes at the two sides of the autoclave, which respectively equipped a great deal of small holes. Steam through these holes evenly spread into the autoclave, heating and stress for merchandise. Holes installation course can promise steam spraying along the wall of autoclave, instead than right sprayed on to the merchandise, guarantee the good quality of goods..
four.eight Drainage
It performs a role of exhausting condensed h2o and is composed of drainage pipeline connector, steam trap, blow-down valve. It connects with the flange in the bottom of autoclave. The condensed h2o is repeatedly exhausted by means of steam lure after sedimentation in the connector. Blow-down can exhaust condensed drinking water and sludge non-scheduled.
4.9 Pressure Factors
- Inlet and exhaust valve, proportionally controlled, CZPT control valve.
- Guide exhaust valve, 3-piece ball valve.
- Stress transducer: one
- Accuracy: +/- 50mbar
- Pressure gauge:one
4.10 Control Technique
- Manage Technique is designed dependent on the study and development towards rubber vulcanization processing market, such as the PLC central managing element, contact display (HIM) procedure system and community, it is a person welcoming, condition of the art, programmable digital system.
- Password guarded entry obtain, operator can log into the technique by accessing the security login form with a title and password.
- It is automatic controlling, recording and graph the temperatures and pressure of the autoclave, audible alarms for substantial or low temperatures or stress.
- Guide operation display makes it possible for operator take guide manage temperature, pressure, and valves as allowed.
- It can insert or help save the product working recipe, exhibit the stress and temperature curve at any time and its paperless report perform can recognize record, preserve and check of technique curve and approach parameters.
- It has more than-temperature and overpressure alarm and a variety of protection security features.
- CZPTer can function sign-up, login and typing in product details, and recognize intranet or distant handle.
- Communication to a Personalized Computer permitted (Teamviewer ), with developed in software program to software, file and graph of procedure in real time.
- Internet connection via Team-Viewer (VPN) with our Company.
four.11 Safety Technique
four.eleven.1 Mechanical safety interlock I
Protection limit handle is interlocked with the lid. Workers have to turn the deal with to unlock the safety device then the lid can be opened.
4.11.2 CZPTal protection interlock II
The protection system functions with security limit handle and connects with our ECC. When workers operate the reducer and safety restrict handle, although there is force in the autoclave, the ECC will give a seem-light-weight alarm.
4.11.3 Security valves
There is one safety valves on the best of autoclave. We have set a force restrict in the valves. When the strain exceed the restrict, the valves will perform automatically to launch the air down to a sensible pressure variety.
5. Configurations of Autoclave
- HMI: Wenview touch monitor, ZheJiang
- PLC: Siemens
- Primary electrical component : Schneider,China
- Limited change: Omron
- AUTOCLAVE Shell: ASME Part VIII, Div 1, CZPT
- CZPT parts: Hualiang, China
Management cupboard according to CE specifications
six. Packing
six.1 The equipment will be appropriately packed / wrapped thinking about long-length ocean and land transportation and rough managing that may possibly happen in the absence of equally functions.
six.two Proper defense from humidity, rust, mould, scratches, shaking, and so on, will be taken so that the items could arrive at the installation website in good problem.
6.3 Shipping marks and warning signed will be plainly painted, and in depth packing record (in English/Espanol) will be soundly attached, to the exterior of the packing.
7. Autoclave Specification
| MODEL SN-LHG2050D VULCANIZATION AUTOCLAVE-TECHNICAL PARAMETER | |||
| No. | Description | Device | Specifications and Parameters |
| one | Effective Working Diameter | mm | 2000 |
| 2 | Effective Working Length | mm | 5000 |
| 3 | Autoclave Track Distance | mm | 800 |
| four | Design Pressure | MPa | 1 |
| 5 | Max. Working Pressure | MPa | .eight |
| six | Safety Valve Exhaust | MPa | .85 |
| seven | Design Temperature | ºC | two hundred |
| 8 | Max. Working Temperature | ºC | a hundred and eighty |
| 9 | Temperature Uniformity at Steady State | ºC | ±2 |
| 10 | Openning CZPT Mode | — | CZPT |
| 11 | Working Medium | — | Saturated steam |
| 12 | Heating Mode | — | Steam immediate heating |
| 13 | Heating Power | KW | 162 |
| fourteen | Quantity of Circulating Fan Motor | Established | one |
| 15 | Quantity of Circulating Fan Motor | KW | 15 |
| 16 | Thermocouple Type | — | Type K or J |
| 17 | Vaccum Lines | Piece | — |
| 18 | Quantity of Vaccum Pressure Transducer | Piece | — |
| 19 | CZPT Control Mode | — | PLC+Computer |
| 20 | Control Software | — | Thermal Processing Control (TPC) |
| 21 | Insulation Type | — | Exterior |
| 22 | Insulation Material | — | Ceramic Fiber |
| 23 | Insulation Thickness | mm | 50 |
| 24 | Insulation Sheet Material | — | Stainless Steel or Aluminized Steel |
| 25 | Working Environment Temperature | ºC | Min. -20ºC, ,Max. +45ºC |
| 26 | Working Environment Humidity | — | <60% |
| 27 | Power Supply | — | 220/380VAC, 3P+N+PE, 50/60Hz |
| 28 | Fat | KG | 7480 |
eight. Expert Workshop
9. CZPT CZPT Turnkey Initiatives
With the experience of manufacture and services for fifteen years, our skilled crew are capable to supply the international turnkey project, such as a specialist training. CZPT autoclaves can be manufactured as ASEM, PED, Advert specifications, as effectively as our Chinese normal.
From the CZPT Group, with fifteen many years of expertise.
