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2500X6000mm Industrial Horizontal Steam Heating Rubber Vulcanizating Autoclave¹

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Product Description 1. Applications of SINOMAC Vulcanization AutoclaveRubber 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 SizeAutoclave model: SN-LHGR2560Effective diameter: 2500mmEffective length: 6000mm Definition: * Effective diameter is the inner diameter of the autoclave. * Effective length is to point to do the actual length of the shell.2.2 Production CapacityWorking circle of autoclave: can be set according to the working processMax size of pulley: ?2000X6000mm2.3 Electric Power Operating voltage: 400V (AC)±5%, 3 phase, 50 Hz Control power: 220VAC/50Hz/24VDC2.4 Water, Air and Steam SupplyCooling water consumption: ~4m3/h Cooling water pressure: min.3 bar ~ max. 6 barControl air of control equipment: 5 ~ 7barSteam capacity: 2t/h2.5 Environmental Conditions Max. air temperature: +50oCMin air temperature: -5oCRelative Humidity: <80%Altitude: <2000m3. General Feature and Working Process3.1. General FeatureAutoclaves 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 Process3.2.1 Standard curing recipe Temp. setpointPress. setpointTemp. step durationPress. step durationSegment1T1P1t 1P-t1Segment2T2P2t 2P-t2Segment3T3P3t 3P-t3Segment4T4P4t 4P-t4Segment5T5P5t 5P-t5Segment6T6 t 6 Segment7T7 t 7 Segment8T8 t 8 Segment9T9 t 9 Segment10T10 t 10 Segment11T11 t 11 Segment12T12 t 12 Segment13T13 t 13 Segment14T14 t 14 Segment15T15 t 15 3.2.2 A short curing recipe example4. Equipment Technical Details4.1 Pressure VesselSINOMAC Pressure Vessel with quick-opening door, can be certified to:CHINESE STANDARD, GB150-2011AMERICAN STANDARD ASME SEC VIII DIV.1 with ASME CertificateEUROPEAN STANDARD PED 97/23/EC with CE certificate.4.2 Door SystemThe 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).4.3 Thermal Insulation SystemInternal Insulation and External InsulationWe 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:Internal insulation layerInsulation material:Ceramic fiber External sheet metal: stainless steel,1.0 mmInsulation thickness:100mm 4.4 Heating SystemThe heating system is a indirect steam kind.The indirect system will be through stainless-steel or copper tubing type heat exchanger placed on the rear side of the autoclave between fan and products. The flow have to move from material to fan, then move front door using vessel side to materialHeating Exchanger material :304 Stainless-steel with aluminum fin or copper tubing aluminum finHeating Exchanger type: Multi-row finned tubing4.5 Air Recirculating SystemHot air circulating ductAnnular air-duct placed on the two side of the autoclave inside as the forward air delivery system. This design features make the temperature more uniform, and working space more big. The Motor fan for circulationThe motor is bolted to the rear of the autoclave, it drives the fan directly.Parameters of circulating fanPower:18.5KW,6-pole, 3phaseConnecting format:direct-connected Rated rotate speed:960r/min(400V/50HZ)Fan wheel:7# centrifugal impeller(Diameter:700mm),Wind pressure:1000Pa, Flow rate:12800 M3/h. Shaft sealingWorking with water cooling to guarantee a long life, the shaft water cooling with separate water pump and flow switch to be fitted to monitor water flow and automatically alarm/stop the cycle if there is not enough water flow. 4.6 Temperature monitoring components Temperature thermocouples: 2 pcs, K type, including HMI monitoring, data-acquisition and control.4.7 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 4.8 Control SystemControl 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.4.9 Safety System 4.9.1 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.4.9.2 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.4.9.3 Safety valvesThere 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 AutoclaveHMI: Wenview touch screen, TAIWANPLC: Siemens Main electrical component : Schneider,ChinaLimited switch: OmronAUTOCLAVE Shell: ASME/PED/GB, SINOMACHydraulic components: Hualiang, ChinaControl cabinet according to CE standards6. System General View (Indirect steam heating)7. Packing8.1 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.8.2 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.8.3 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.8. Autoclave Specification MODEL SN-LHG2560 VULCANIZATION AUTOCLAVE-TECHNICAL PARAMETERNo.DescriptionUnitSpecifications and Parameters1Effective Working Diametermm25002Effective Working Lengthmm60003Autoclave Track Distancemm9004Design PressureMPa15Max. Working PressureMPa0.86Safety Valve ExhaustMPa0.857Design TemperatureoC2008Max. Working TemperatureoC1809Temperature Uniformity at Steady StateoC±210Openning Door Mode---Hydraulic11Working Medium---Compressed air12Heating Mode---Steam indirect heating13Heating PowerKW16214Quantity of Circulating Fan MotorSet115Quantity of Circulating Fan MotorKW1516Thermocouple Type---Type K or J17Vaccum LinesPiece---18Quantity of Vaccum Pressure TransducerPiece---19Standard Control Mode---PLC+PC20Control Software--- Thermal Processing Control (TPC)21Insulation Type---Internal22Insulation Material---Ceramic Fiber23Insulation Thicknessmm7524Insulation Sheet Material---Stainless Steel or Aluminized Steel25Working Environment TemperatureoCMin. -20oC, ,Max. +45oC26Working Environment Humidity---<60%27Power Supply---400VAC, 3P+N+PE, 50/60Hz28WeightKG165009. Professional Workshop10. SINOMAC Global Turnkey ProjectsWith 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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