1. Purposes of CZPT Vulcanization Autoclave
Rubber vulcanization is a chemical process at a presented force, temperature and time for changing normal rubber into a lot more durable components by the addition of sulfur. These additives modify the polymer by forming cross-links (bridges) between specific polymer chains. Vulcanized components are significantly less sticky and have outstanding mechanical homes. And vulcanization autoclave is utilised widely for this chemical process. The main goods are galoshes, rubber tubes, cable, rubber roller, rubber ball, and many others.In this discipline, CZPT has been the chief, as we have gathered full vulcanization encounter and technological innovation for several several years.
two. Basic Design Data
2.1 Model and Dimensions
- Autoclave product: SN-LHGR2560
- Efficient diameter: 2500mm
- Powerful size: 6000mm
Definition: * Effective diameter is the interior diameter of the autoclave.
* Efficient length is to stage to do the genuine length of the shell.
two.two Production Potential
- Functioning circle of autoclave: can be set in accordance to the doing work method
- Max dimension of pulley: Ø2000X6000mm
two.3 CZPT Electricity
- Running voltage: 400V (AC)±5%, three period, fifty Hz
- Manage energy: 220VAC/50Hz/24VDC
2.four Water, Air and Steam Provide
- Cooling water consumption: ~4mthree/h
- Cooling drinking water strain: min.three bar ~ max. 6 bar
- Handle air of management equipment: 5 ~ 7bar
- Steam capability: 2t/h
2.five Environmental Problems
- Max. air temperature: +50ºC
- Min air temperature: -5ºC
- Relative Humidity: <80%
- Altitude: <2000m
three. CZPT Function and Functioning Method
three.one. CZPT Feature
Autoclaves with immediate steam: heating and pressurization are carried out with steam. This heating program is notably effective and indicated for goods of massive sizes and excess weight. The temperature uniformity which usually differs in between ±2°C,the exchange ability, occurring with condensation on colder surfaces, coupled with tested installations, allow to obtain excellent final results.
3.2 Working Approach
three.two.one CZPT curing recipe
| Temp. setpoint | Push. setpoint | Temp. action period | Press. step period | |
| Segment1 | T1 | P1 | t 1 | P-t1 |
| Segment2 | T2 | P2 | t 2 | P-t2 |
| Segment3 | T3 | P3 | t three | P-t3 |
| Segment4 | T4 | P4 | t 4 | P-t4 |
| Segment5 | T5 | P5 | t five | P-t5 |
| Segment6 | T6 | t six | ||
| Segment7 | T7 | t seven | ||
| Segment8 | T8 | t 8 | ||
| Segment9 | T9 | t nine | ||
| Segment10 | T10 | t 10 | ||
| Segment11 | T11 | t eleven | ||
| Segment12 | T12 | t twelve | ||
| Segment13 | T13 | t thirteen | ||
| Segment14 | T14 | t fourteen | ||
| Segment15 | T15 | t fifteen |
3.2.two A brief curing recipe instance
four. Products CZPT Information
4.1 Pressure Vessel
- Force vessel with swift-opening doorway, Style, Manufacture & Inspection: Code ASME Section VIII, Div 1.
- Shell Materials: SA-516
- Cap Flange Materials: ASTM-105 Forged
- Shell Flange Materials: ASTM-a hundred and five Forged
- Radiography Degree: a hundred% welding radiographic documents are incorporated
- ASME stamping , Character Of Inspection:a. Overview the layout drawing and calculation sheet
b. Verification of the content
c. Overview welding procedure
d. Review welder qualification
e. Overview NDT staff qualification
f. Assessment NDT documentation
g. Hydrostatic examination
four.2 CZPT System
- The closing program of the autoclave is the indented kind assisted with a hydraulic method, in order to quickly and secured make a totally airtight closing.
- The entire method is made up of 3 elements: a pair of equipment flange, pushed devices and seal ring.
- CZPTally operated doorway opening and closing. It is controlled by PLC technique.
- The seal ring is produced of silicon rubber.
- Protection stress sensors have to avoid doorway opening in case of stress (authorized much less than .1 bars).
4.3 Thermal Insulation System
Internal Insulation and Exterior Insulation
We use ceramic fiber as the insulation content. The heat transfer coefficient is very minimal to make the warmth decline to a least. The covering board of ceramic fiber is stainless steel. It is corrosion resistant and seems nice. Internal insulation design and style can get a reduced strength consumption, even though exterior insulation design will get a substantial 1, but a better temperature uniformity.
- Insulation:Internal insulation layer
- Insulation materials:Ceramic fiber
- External sheet metallic: stainless steel,one. mm
- Insulation thickness:100mm
4.4 Heating Method
- The heating method is a oblique steam sort.
- The oblique method will be by way of stainless-steel or copper tubing variety warmth exchanger positioned on the rear aspect of the autoclave in between enthusiast and items. The movement have to shift from material to fan, then shift front doorway making use of vessel facet to materials
- Heating Exchanger material :304 Stainless-steel with aluminum fin or copper tubing aluminum fin
- Heating Exchanger type: Multi-row finned tubing
4.five Air Recirculating Method
- Sizzling air circulating duct
Annular air-duct placed on the two aspect of the autoclave inside as the CZPT air shipping system. This style features make the temperature a lot more uniform, and operating place a lot more massive. - The Motor enthusiast for circulation
The motor is bolted to the rear of the autoclave, it drives the enthusiast directly. - Parameters of circulating enthusiast
Electricity:eighteen.5KW,6-pole, 3phase
Connecting format:immediate-linked
Rated rotate pace:960r/min(400V/50HZ)
Enthusiast wheel:seven# centrifugal impeller(Diameter:700mm),
Wind strain:1000Pa,
Flow rate:12800 M3/h. - Shaft sealing
Operating with water cooling to guarantee a long life, the shaft h2o cooling with different h2o pump and circulation switch to be equipped to check water flow and immediately alarm/cease the cycle if there is not enough h2o stream.
4.6 Temperature checking components
Temperature thermocouples: two pcs, K type, such as HMI checking, info-acquisition and control.
4.7 Pressure Elements
- Inlet and exhaust valve, proportionally controlled, CZPT handle valve.
- Handbook exhaust valve, 3-piece ball valve.
- Force transducer: one
- Precision: +/- 50mbar
- Stress gauge:1
4.8 Control Program
- Management System is created dependent on the study and growth towards rubber vulcanization processing market, which includes the PLC central managing portion, touch screen (HIM) procedure technique and network, it is a consumer pleasant, condition of the art, programmable digital system.
- Password protected entry access, operator can log into the technique 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 reduced temperatures or pressure.
- Guide operation screen makes it possible for operator take manual handle temperature, strain, and valves as authorized.
- It can insert or save the product working recipe, display the stress and temperature curve at any time and its paperless file purpose can realize record, conserve and examine of technique curve and procedure parameters.
- It has above-temperature and overpressure alarm and different basic safety safety functions.
- CZPTer can work sign up, login and typing in item details, and recognize intranet or distant handle.
- Interaction to a Personal Computer allowed (Teamviewer ), with built in application to software, file and graph of method in true time.
- Internet connection by way of Team-Viewer (VPN) with our Company.
4.9 Safety Program
four.nine.1 Mechanical basic safety interlock I
Protection restrict manage is interlocked with the lid. Workers have to switch the deal with to unlock the safety system then the lid can be opened.
four.nine.2 CZPTal basic safety interlock II
The safety device works with basic safety restrict manage and connects with our ECC. When employees operate the reducer and protection restrict manage, whilst there is pressure in the autoclave, the ECC will give a sound-gentle alarm.
4.9.three Protection valves
There is one safety valves on the prime of autoclave. We have set a force restrict in the valves. When the strain exceed the restrict, the valves will work automatically to launch the air down to a affordable pressure selection.
five. Configurations of Autoclave
- HMI: Wenview touch screen, ZheJiang
- PLC: Siemens
- Major electrical part : Schneider,China
- Constrained change: Omron
- AUTOCLAVE Shell: ASME Part VIII, Div one, CZPT
- CZPT elements: Hualiang, China
Control cupboard in accordance to CE expectations
6. Equivalency of CZPTs and Codes
Reference Codes and CZPTs
6.1 ASME Boiler and Force Vessel Code (BPVC), Part VIII, Division 1: Policies for CZPT of Pressure Vessels
six.2 AS 1210 – 2571 Force Vessels
six.3 AS 4343 – 2005 Force Products – Hazard Ranges
six.four AS 3873 – 2001 Strain Gear – Operation and Upkeep
seven. System CZPT Check out (Indirect steam heating)
eight. Packing
eight.one The products will be correctly packed / wrapped contemplating extended-distance ocean and land transportation and rough handling that could happen in the absence of equally events.
8.two Proper security from humidity, rust, mildew, scratches, shaking, and so forth, will be taken so that the items could get there at the set up internet site in very good situation.
eight.three Shipping marks and warning signed will be plainly painted, and thorough packing record (in English/Espanol) will be soundly hooked up, to the exterior of the packing.
nine. Autoclave Specification
| MODEL SN-LHG2560 VULCANIZATION AUTOCLAVE-TECHNICAL PARAMETER | |||
| No. | Description | Device | Specifications and Parameters |
| one | Effective Working Diameter | mm | 2500 |
| 2 | Effective Working Length | mm | 6000 |
| three | Autoclave Track Distance | mm | 900 |
| four | Design Pressure | MPa | one |
| five | Max. Working Pressure | MPa | .8 |
| 6 | Safety Valve Exhaust | MPa | .eighty five |
| seven | Design Temperature | ºC | two hundred |
| 8 | Max. Working Temperature | ºC | a hundred and eighty |
| nine | Temperature Uniformity at Steady State | ºC | ±2 |
| 10 | Openning CZPT Mode | — | CZPT |
| 11 | Working Medium | — | Compressed air |
| twelve | Heating Mode | — | Steam indirect heating |
| thirteen | Heating Power | KW | 162 |
| fourteen | Quantity of Circulating Fan Motor | Set | one |
| 15 | Quantity of Circulating Fan Motor | KW | fifteen |
| 16 | Thermocouple Type | — | Type K or J |
| 17 | Vaccum Lines | Piece | — |
| eighteen | Quantity of Vaccum Pressure Transducer | Piece | — |
| 19 | CZPT Control Mode | — | PLC+Personal computer |
| 20 | Control Software | — | Thermal Processing Control (TPC) |
| 21 | Insulation Type | — | Internal |
| 22 | Insulation Material | — | Ceramic Fiber |
| 23 | Insulation Thickness | mm | 75 |
| 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 | — | 400VAC, 3P+N+PE, 50/60Hz |
| 28 | Bodyweight | KG | 16500 |
ten. Skilled Workshop
eleven. CZPT CZPT Turnkey Projects
With the experience of manufacture and services for fifteen several years, our specialist crew are in a position to offer you the world-wide turnkey undertaking, including a professional education. CZPT autoclaves can be made as ASEM, PED, Advert standards, as well as our Chinese normal.
From the CZPT Crew, with 15 several years of expertise.
