one. Applications of CZPT Vulcanization Autoclave
Rubber vulcanization is a chemical process at a presented strain, temperature and time for changing normal rubber into more sturdy materials by the addition of sulfur. These additives modify the polymer by forming cross-links (bridges) amongst individual polymer chains. Vulcanized supplies are much less sticky and have outstanding mechanical properties. And vulcanization autoclave is used broadly for this chemical process. The principal goods are galoshes, rubber tubes, cable, rubber roller, rubber ball, and so forth.In this area, CZPT has been the leader, as we have accrued complete vulcanization experience and technology for a lot of many years.
2. Standard Design and style Knowledge
2.1 Model and Measurement
- Autoclave design: SN-LHGR2050D
- Successful diameter: 2000mm
- Efficient duration: 5000mm
Definition: * Effective diameter is the interior diameter of the autoclave.
* Successful length is to level to do the actual length of the shell.
2.two Creation Ability
- Doing work circle of autoclave: can be set in accordance to the functioning process
- Max size of pulley: Ø1700X5000mm
2.3 CZPT Electrical power
- Operating voltage: 415V (AC)±5%, 3 section, fifty Hz
- Manage electrical power: 220VAC/50Hz/24VDC
two.4 Drinking water, Air and Steam Source
- Cooling water use: ~2mthree/h
- Cooling h2o force: min.three bar ~ max. six bar
- Manage air of control tools: 5 ~ 7bar
- Steam potential: 2t/h
2.five Environmental Conditions
- Max. air temperature: +50ºC
- Min air temperature: -5ºC
- Relative Humidity: <80%
- Altitude: <2000m
3. CZPT Attribute and Functioning Process
3.one. CZPT Attribute
Autoclaves with direct steam: heating and pressurization are carried out with steam. This heating system is specifically effective and indicated for items of large sizes and bodyweight. The temperature uniformity which usually may differ among +/- 2°C,the trade potential, happening with condensation on colder surfaces, coupled with examined installations, allow to obtain excellent benefits.
3.2 Operating Method
three.2.one CZPT curing recipe
|Item||Temp. setpoint||Soak Time||Temp. action duration|
|Segment1||T1||t 1-2||t 1|
|Segment2||T2||t 3-four||t 2|
|Segment3||T3||t 5-6||t 3|
three.2.two A short curing recipe case in point
4. Gear CZPT Specifics
four.1 Pressure Vessel
- Stress vessel with swift-opening doorway, Design, Manufacture & Inspection: Code ASME Section VIII, Div one.
- Shell Materials: SA-516
- Cap Flange Substance: ASTM-one zero five Forged
- Shell Flange Content: ASTM-a hundred and five Forged
- Radiography Level: one hundred% welding radiographic records are incorporated
- ASME stamping , Nature Of Inspection:a. Assessment the layout drawing and calculation sheet
b. Verification of the materials
c. Evaluation welding method
d. Assessment welder qualification
e. Review NDT personnel qualification
f. Assessment NDT documentation
g. Hydrostatic test
four.2 CZPT System
- The closing system of the autoclave is the indented type assisted with a hydraulic program, in get to speedily and secured make a absolutely airtight closing.
- The whole technique is composed of a few parts: a pair of equipment flange, driven products and seal ring.
- CZPTally operated doorway opening and closing. It is controlled by PLC technique.
- The seal ring is manufactured of silicon rubber.
- Security strain sensors have to avert doorway opening in scenario of pressure (authorized significantly less than .1 bars).
4.3 Thermal Insulation Program
Inside Insulation and External Insulation
We use ceramic fiber as the insulation materials. The heat transfer coefficient is really lower to make the warmth reduction to a least. The covering board of ceramic fiber is stainless metal. It is corrosion resistant and seems to be good. Interior insulation design and style can get a low vitality consumption, although external insulation design and style receives a large one particular, but a better temperature uniformity.
- Insulation:External insulation layer
- Insulation substance:Ceramic fiber
- Exterior sheet metallic: stainless metal,one. mm
- Insulation thickness:50mm
four.4 Internal Coating
- Function: Anti-corrosion
- Spraying procedure: Aluminum coating
four.5 Hot Air Circulating Technique
We use modified centrifugal impellers, which can generate large air stream and higher air strain. And we undertake a dynamic and mechanical sealing design and style. The dynamic and static ring sealing substance is silicon carbide-graphite.
The layout of air duct structure is a U type with circulation guiding system, which can guarantee the adequacy of very hot air circulation. The compelled convection fee within the autoclave can reach far more than 90%. By this design, the system can get a regular and uniform temperature increasing price.
four.5 Internal Rails and Factors
- Rails: 100x75X8mm Angle, stainless metal
- Steam spray pipe:stainless steel
- Pipe joints on autoclave: stainless steel
4.7 Direct Steam Heating and Pressurization
There are two steam distribution pipes at the two sides of the autoclave, which respectively equipped a lot of little holes. Steam through these holes evenly unfold into the autoclave, heating and stress for item. Holes set up route can guarantee steam spraying together the wall of autoclave, fairly than right sprayed on to the product, guarantee the high quality of merchandise..
It performs a position of exhausting condensed drinking water and is made up of drainage pipeline connector, steam trap, blow-down valve. It connects with the flange in the bottom of autoclave. The condensed water is constantly fatigued via steam lure following sedimentation in the connector. Blow-down can exhaust condensed water and sludge non-scheduled.
4.9 Pressure Factors
- Inlet and exhaust valve, proportionally controlled, CZPT handle valve.
- Manual exhaust valve, three-piece ball valve.
- Force transducer: 1
- Precision: +/- 50mbar
- Stress gauge:1
four.10 Control System
- Handle System is created primarily based on the analysis and growth towards rubber vulcanization processing sector, which includes the PLC central controlling portion, touch monitor (HIM) procedure program and community, it is a consumer friendly, point out of the artwork, programmable digital system.
- Password safeguarded entry access, operator can log into the system by accessing the security login form with a title and password.
- It is automatic managing, recording and graph the temperatures and stress of the autoclave, audible alarms for large or minimal temperatures or stress.
- Guide procedure display screen makes it possible for operator take guide management temperature, force, and valves as permitted.
- It can insert or conserve the product working recipe, show the strain and temperature curve at any time and its paperless file perform can recognize file, conserve and check out of approach curve and method parameters.
- It has in excess of-temperature and overpressure alarm and different protection safety functions.
- CZPTer can operate sign up, login and typing in merchandise details, and realize intranet or remote control.
- Communication to a Personal Computer permitted (Teamviewer ), with created in software program to program, report and graph of method in real time.
- Internet connection through Crew-Viewer (VPN) with our Company.
4.11 Safety Technique
4.eleven.1 Mechanical safety interlock I
Protection restrict manage is interlocked with the lid. Workers have to turn the deal with to unlock the safety unit then the lid can be opened.
4.eleven.2 CZPTal protection interlock II
The protection unit works with basic safety restrict deal with and connects with our ECC. When employees run the reducer and protection restrict take care of, while there is stress in the autoclave, the ECC will give a sound-light-weight alarm.
four.eleven.three Basic safety valves
There is one safety valves on the top of autoclave. We have set a pressure limit in the valves. When the strain exceed the limit, the valves will operate routinely to launch the air down to a realistic force variety.
5. Configurations of Autoclave
- HMI: Wenview contact display, ZheJiang
- PLC: Siemens
- Primary electrical component : Schneider,China
- Minimal change: Omron
- AUTOCLAVE Shell: ASME Area VIII, Div one, CZPT
- CZPT elements: Hualiang, China
Control cupboard according to CE standards
six.Technique CZPT View
six.one The tools will be properly packed / wrapped taking into consideration long-length ocean and land transportation and rough managing that might come about in the absence of each get-togethers.
six.two Proper security from moisture, rust, mildew, scratches, shaking, and so on, will be taken so that the merchandise could arrive at the installation website in very good condition.
6.three Shipping marks and warning signed will be plainly painted, and detailed packing list (in English/Espanol) will be soundly connected, to the outside of the packing.
eight. Autoclave Specification
|MODEL SN-LHG2050D VULCANIZATION AUTOCLAVE-TECHNICAL PARAMETER|
|No.||Description||Unit||Specifications and Parameters|
|1||Effective Working Diameter||mm||2000|
|two||Effective Working Length||mm||5000|
|3||Autoclave Track Distance||mm||800|
|5||Max. Working Pressure||MPa||.eight|
|6||Safety Valve Exhaust||MPa||.eighty five|
|8||Max. Working Temperature||ºC||one hundred eighty|
|nine||Temperature Uniformity at Steady State||ºC||±2|
|10||Openning CZPT Mode||—||CZPT|
|11||Working Medium||—||Saturated steam|
|12||Heating Mode||—||Steam direct heating|
|14||Quantity of Circulating Fan Motor||Established||one|
|15||Quantity of Circulating Fan Motor||KW||fifteen|
|sixteen||Thermocouple Type||—||Type K or J|
|eighteen||Quantity of Vaccum Pressure Transducer||Piece||—|
|19||CZPT Control Mode||—||PLC+Laptop|
|20||Control Software||—||Thermal Processing Control (TPC)|
|22||Insulation Material||—||Ceramic Fiber|
|24||Insulation Sheet Material||—||Stainless Steel or Aluminized Steel|
|twenty five||Working Environment Temperature||ºC||Min. -20ºC, ,Max. +45ºC|
|26||Working Environment Humidity||—||<60%|
|27||Power Supply||—||220/380VAC, 3P+N+PE, 50/60Hz|
eight. Specialist Workshop
9. CZPT CZPT Turnkey Initiatives
With the encounter of manufacture and provider for fifteen several years, our skilled crew are capable to supply the global turnkey undertaking, such as a skilled coaching. CZPT autoclaves can be created as ASEM, PED, Advertisement requirements, as nicely as our Chinese standard.
From the CZPT Crew, with fifteen years of experience.