2000X5000mm Steam Direct Heating Rubber Vulcanization Autoclave
China 2000X5000mm Steam Direct Heating Rubber Vulcanization Autoclave, Find details about China Rubber Vulcanization Autoclave, Autoclave from 2000X5000mm Steam Direct Heating Rubber Vulcanization Autoclave
Basic Info.
Model NO.
SN-LHG2050D
Max. Working Pressure
0.8 MPa (8 Bar)
Design Temperature
200 ºC
Max. Working Temperature
180 ºC
Heating Mode
Steam Direct Heating
Control Mode
PLC+PC
Control Software
Tpc (Thermal Processing Control )
Voltage
380/400/415/440/480/600VAC
Insulation Material
Ceramic Fiber
Weight
7480 Kg
Trademark
SINOMAC or OEM
Transport Package
Standard Seaworthy Package
Specification
2000X5000mm
Origin
Changzhou, China
HS Code
84778000
Model NO.
SN-LHG2050D
Max. Working Pressure
0.8 MPa (8 Bar)
Design Temperature
200 ºC
Max. Working Temperature
180 ºC
Heating Mode
Steam Direct Heating
Control Mode
PLC+PC
Control Software
Tpc (Thermal Processing Control )
Voltage
380/400/415/440/480/600VAC
Insulation Material
Ceramic Fiber
Weight
7480 Kg
Trademark
SINOMAC or OEM
Transport Package
Standard Seaworthy Package
Specification
2000X5000mm
Origin
Changzhou, China
HS Code
84778000
Product Desciption
1. Applications of SINOMAC Vulcanization Autoclave
Rubber vulcanization is a chemical process at a given pressure, temperature and time for converting natural rubber into more durable materials by the addition of sulfur. These additives modify the polymer by forming cross-links (bridges) between individual polymer chains. Vulcanized materials are less sticky and have superior mechanical properties. And vulcanization autoclave is used widely for this chemical process. The main products are galoshes, rubber tubes, cable, rubber roller, rubber ball, etc.In this field, SINOMAC has been the leader, as we have accumulated full vulcanization experience and technology for many years.
2. Basic Design Data
2.1 Model and Size
3.1. General Feature
Autoclaves with direct steam: heating and pressurization are carried out with steam. This heating system is particularly effective and indicated for products of large sizes and weight. The temperature uniformity which normally varies between +/- 2°C,the exchange capacity, occurring with condensation on colder surfaces, coupled with tested installations, allow to obtain excellent results.
3.2 Working Process
3.2.1 Standard curing recipe
3.2.2 A short curing recipe example
4. Equipment Technical Details
4.1 Pressure Vessel
SINOMAC Pressure vessel with quick-opening door, can be certified to:
Internal Insulation and External Insulation
We use ceramic fiber as the insulation material. The heat transfer coefficient is very low to make the heat loss to a minimum. The covering board of ceramic fiber is stainless steel. It is corrosion resistant and looks nice. Internal insulation design can get a low energy consumption, while external insulation design gets a high one, but a better temperature uniformity.
4.4 Internal Coating
We use modified centrifugal impellers, which can generate large air flow and high air pressure. And we adopt a dynamic and mechanical sealing design. The dynamic and static ring sealing material is silicon carbide-graphite.
The design of air duct structure is a U type with flow guiding device, which can ensure the adequacy of hot air circulation. The forced convection rate inside the autoclave can reach more than 90%. By this design, the system can obtain a steady and uniform temperature rising rate.
4.5 Internal Rails and Components
4.11 Safety System
6. Packing
6.1 The equipment will be properly packed / wrapped considering long-distance ocean and land transportation and rough handling that may happen in the absence of both parties.
6.2 Proper protection from moisture, rust, mold, scratches, shaking, etc, will be taken so that the goods may arrive at the installation site in good condition.
6.3 Shipping marks and warning signed will be clearly painted, and detailed packing list (in English/Espanol) will be soundly attached, to the outside of the packing.
7. Autoclave Specification
8. Professional Workshop
9. SINOMAC Global Turnkey Projects
With the experience of manufacture and service for 15 years, our professional team are able to offer the global turnkey project, including a professional training. SINOMAC autoclaves can be made as ASEM, PED, AD standards, as well as our Chinese standard.
From the SINOMAC Team, with 15 years of experience.
Rubber vulcanization is a chemical process at a given pressure, temperature and time for converting natural rubber into more durable materials by the addition of sulfur. These additives modify the polymer by forming cross-links (bridges) between individual polymer chains. Vulcanized materials are less sticky and have superior mechanical properties. And vulcanization autoclave is used widely for this chemical process. The main products are galoshes, rubber tubes, cable, rubber roller, rubber ball, etc.In this field, SINOMAC has been the leader, as we have accumulated full vulcanization experience and technology for many years.
2. Basic Design Data
2.1 Model and Size
- Autoclave model: SN-LHGR2050D
- Effective diameter: 2000mm
- Effective length: 5000mm
* Effective length is to point to do the actual length of the shell.
2.2 Production Capacity
2.2 Production Capacity
- Working circle of autoclave: can be set according to the working process
- Max size of pulley: Ø1700X5000mm
- Operating voltage: 415V (AC)±5%, 3 phase, 50 Hz
- Control power: 220VAC/50Hz/24VDC
- Cooling water consumption: ~2m3/h
- Cooling water pressure: min.3 bar ~ max. 6 bar
- Control air of control equipment: 5 ~ 7bar
- Steam capacity: 2t/h
- Max. air temperature: +50ºC
- Min air temperature: -5ºC
- Relative Humidity: <80%
- Altitude: <2000m
3.1. General Feature
Autoclaves with direct steam: heating and pressurization are carried out with steam. This heating system is particularly effective and indicated for products of large sizes and weight. The temperature uniformity which normally varies between +/- 2°C,the exchange capacity, occurring with condensation on colder surfaces, coupled with tested installations, allow to obtain excellent results.
3.2 Working Process
3.2.1 Standard curing recipe
| Item | Temp. setpoint | Soak Time | Temp. step duration |
| Segment1 | T1 | t 1-2 | t 1 |
| Segment2 | T2 | t 3-4 | t 2 |
| Segment3 | T3 | t 5-6 | t 3 |
3.2.2 A short curing recipe example
4. Equipment Technical Details
4.1 Pressure Vessel
SINOMAC Pressure vessel with quick-opening door, can be certified to:
- CHINESE STANDARD, GB150-2011
- AMERICAN STANDARD ASME SEC VIII DIV.1 with ASME Certificate
- EUROPEAN STANDARD PED 97/23/EC with CE certificate.
- The closing system of the autoclave is the indented kind assisted with a hydraulic system, in order to quickly and secured make a totally hermetic closing.
- The whole system consists of three parts: a pair of gear flange, driven devices and seal ring.
- Hydraulically operated door opening and closing. It is controlled by PLC system.
- The seal ring is made of silicon rubber.
- Safety pressure sensors have to prevent door opening in case of pressure (allowed less than 0.1 bars).
Internal Insulation and External Insulation
We use ceramic fiber as the insulation material. The heat transfer coefficient is very low to make the heat loss to a minimum. The covering board of ceramic fiber is stainless steel. It is corrosion resistant and looks nice. Internal insulation design can get a low energy consumption, while external insulation design gets a high one, but a better temperature uniformity.
- Insulation:External insulation layer
- Insulation material:Ceramic fiber
- External sheet metal: stainless steel,1.0 mm
- Insulation thickness:50mm
4.4 Internal Coating
- Purpose: Anti-corrosion
- Spraying process: Aluminum coating
- Thickness:0.15-0.2mm
We use modified centrifugal impellers, which can generate large air flow and high air pressure. And we adopt a dynamic and mechanical sealing design. The dynamic and static ring sealing material is silicon carbide-graphite.
The design of air duct structure is a U type with flow guiding device, which can ensure the adequacy of hot air circulation. The forced convection rate inside the autoclave can reach more than 90%. By this design, the system can obtain a steady and uniform temperature rising rate.
4.5 Internal Rails and Components
- Rails: 100x75X8mm Angle, stainless steel
- Steam spray pipe:stainless steel
- Pipe joints on autoclave: stainless steel
There are two steam distribution pipes at the two sides of the autoclave, which respectively equipped a lot of small holes. Steam through these holes evenly spread into the autoclave, heating and pressure for product. Holes installation direction can guarantee steam spraying along the wall of autoclave, rather than directly sprayed onto the product, guarantee the quality of products..
4.8 Drainage
It plays a role of exhausting condensed water and consists of drainage pipeline connector, steam trap, blow-down valve. It connects with the flange in the bottom of autoclave. The condensed water is continuously exhausted through steam trap after sedimentation in the connector. Blow-down can exhaust condensed water and sludge non-scheduled.
4.9 Pressure Components
4.8 Drainage
It plays a role of exhausting condensed water and consists of drainage pipeline connector, steam trap, blow-down valve. It connects with the flange in the bottom of autoclave. The condensed water is continuously exhausted through steam trap after sedimentation in the connector. Blow-down can exhaust condensed water and sludge non-scheduled.
4.9 Pressure Components
- Inlet and exhaust valve, proportionally controlled, Electric control valve.
- Manual exhaust valve, 3-piece ball valve.
- Pressure transducer: 1
- Accuracy: +/- 50mbar
- Pressure gauge:1
- Control System is developed based on the research and development toward rubber vulcanization processing industry, including the PLC central controlling part, touch screen (HIM) operation system and network, it is a user friendly, state of the art, programmable digital system.
- Password protected entry access, operator can log into the system by accessing the security login form with a name and password.
- It is automatic controlling, recording and graph the temperatures and pressure of the autoclave, audible alarms for high or low temperatures or pressure.
- Manual operation screen allows operator take manual control temperature, pressure, and valves as allowed.
- It can insert or save the product working recipe, display the pressure and temperature curve anytime; and its paperless record function can realize record, save and check of technique curve and process parameters.
- It has over-temperature and overpressure alarm and various safety protection functions.
- Customer can operate register, login and typing in product information, and realize intranet or remote control.
- Communication to a Personal Computer allowed (Teamviewer ), with built in software to program, record and graph of process in real time.
- Internet connection via Team-Viewer (VPN) with our Company.
4.11 Safety System
4.11.1 Mechanical safety interlock I
Safety limit handle is interlocked with the lid. Workers have to turn the handle to unlock the safety device then the lid can be opened.
4.11.2 Electrical safety interlock II
The safety device works with safety limit handle and connects with our ECC. When workers operate the reducer and safety limit handle, while there is pressure in the autoclave, the ECC will give a sound-light alarm.
4.11.3 Safety valves
There is one safety valves on the top of autoclave. We have set a pressure limit in the valves. When the pressure exceed the limit, the valves will work automatically to release the air down to a reasonable pressure range.
5. Configurations of Autoclave
Safety limit handle is interlocked with the lid. Workers have to turn the handle to unlock the safety device then the lid can be opened.
4.11.2 Electrical safety interlock II
The safety device works with safety limit handle and connects with our ECC. When workers operate the reducer and safety limit handle, while there is pressure in the autoclave, the ECC will give a sound-light alarm.
4.11.3 Safety valves
There is one safety valves on the top of autoclave. We have set a pressure limit in the valves. When the pressure exceed the limit, the valves will work automatically to release the air down to a reasonable pressure range.
5. Configurations of Autoclave
- HMI: Wenview touch screen, TAIWAN
- PLC: Siemens
- Main electrical component : Schneider,China
- Limited switch: Omron
- AUTOCLAVE Shell: ASME Section VIII, Div 1, SINOMAC
- Hydraulic components: Hualiang, China
6. Packing
6.1 The equipment will be properly packed / wrapped considering long-distance ocean and land transportation and rough handling that may happen in the absence of both parties.
6.2 Proper protection from moisture, rust, mold, scratches, shaking, etc, will be taken so that the goods may arrive at the installation site in good condition.
6.3 Shipping marks and warning signed will be clearly painted, and detailed packing list (in English/Espanol) will be soundly attached, to the outside of the packing.
7. Autoclave Specification
| MODEL SN-LHG2050D VULCANIZATION AUTOCLAVE-TECHNICAL PARAMETER | |||
| No. | Description | Unit | Specifications and Parameters |
| 1 | Effective Working Diameter | mm | 2000 |
| 2 | Effective Working Length | mm | 5000 |
| 3 | Autoclave Track Distance | mm | 800 |
| 4 | Design Pressure | MPa | 1 |
| 5 | Max. Working Pressure | MPa | 0.8 |
| 6 | Safety Valve Exhaust | MPa | 0.85 |
| 7 | Design Temperature | ºC | 200 |
| 8 | Max. Working Temperature | ºC | 180 |
| 9 | Temperature Uniformity at Steady State | ºC | ±2 |
| 10 | Openning Door Mode | --- | Hydraulic |
| 11 | Working Medium | --- | Saturated steam |
| 12 | Heating Mode | --- | Steam direct heating |
| 13 | Heating Power | KW | 162 |
| 14 | Quantity of Circulating Fan Motor | Set | 1 |
| 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 | Standard Control Mode | --- | PLC+PC |
| 20 | Control Software | --- | Thermal Processing Control (TPC) |
| 21 | Insulation Type | --- | External |
| 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 | Weight | KG | 7480 |
8. Professional Workshop
9. SINOMAC Global Turnkey Projects
With the experience of manufacture and service for 15 years, our professional team are able to offer the global turnkey project, including a professional training. SINOMAC autoclaves can be made as ASEM, PED, AD standards, as well as our Chinese standard.
From the SINOMAC Team, with 15 years of experience.
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