1500X3000mm ASME Certified Electric Heating Rubber Vulcanizer (SN-LHGR1530)

Model NO.: SN-LHGR1530
Design Temperature: 180 ºC
Max. Working Temperature: 160 ºC
Heating Mode: Electric/Steam/Thermal Oil
Control Mode: PLC+PC
Control Software: Tpc (Thermal Processing Control)
Voltage: 380/400/415/440/480/600VAC
Insulation Material: Ceramic Fiber
Weight: 3260 Kg
Trademark: SINOMAC or OEM
Transport Package: Standard Seaworthy Package
Specification: 1500X3000mm
Origin: Changzhou, China
HS Code: 84778000
Model NO.: SN-LHGR1530
Design Temperature: 180 ºC
Max. Working Temperature: 160 ºC
Heating Mode: Electric/Steam/Thermal Oil
Control Mode: PLC+PC
Control Software: Tpc (Thermal Processing Control)
Voltage: 380/400/415/440/480/600VAC
Insulation Material: Ceramic Fiber
Weight: 3260 Kg
Trademark: SINOMAC or OEM
Transport Package: Standard Seaworthy Package
Specification: 1500X3000mm
Origin: Changzhou, China
HS Code: 84778000
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.

1500X3000mm ASME Certified Electric Heating Rubber Vulcanizer (SN-LHGR1530)

2.  SINOMAC Leading Position in the Industry

In order to get high-quality rubber rolls, it is very necessary to directly vulcanize the rubber rolls with metal supports inside. This modified treatment is processed in SINOMAC rubber vulcanization autoclave. Inside the autoclave, the pressure, temperature and time can be controlled effectively without the help of moulds. In this field, SINOMAC has been the leader, as we have accumulated full vulcanization experience and technology for many years.

3. General Feature and Working Process

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
  Temp. setpoint Press. setpoint Temp. step duration Press. step duration
Segment1 T1 P1 t 1 P-t1
Segment2 T2 P2 t 2 P-t2
Segment3 T3 P3 t 3 P-t3
Segment4 T4 P4 t 4 P-t4
Segment5 T5 P5 t 5 P-t5
Segment6 T6   t 6  
Segment7 T7   t 7  
Segment8 T8   t 8  
Segment9 T9   t 9  
Segment10 T10   t 10  
Segment11 T11   t 11  
Segment12 T12   t 12  
Segment13 T13   t 13  
Segment14 T14   t 14  
Segment15 T15   t 15  

3.2.2 A short curing recipe example

1500X3000mm ASME Certified Electric Heating Rubber Vulcanizer (SN-LHGR1530)

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.
4.2 Door System
  • 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).
4.3 Thermal Insulation System

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:Internal insulation layer
  • Insulation material:Ceramic fiber 
  • External sheet metal: stainless steel,1.0 mm
  • Insulation thickness:100mm
 4.4 Heating System
  • The 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 material
  • Heating Exchanger material :304 Stainless-steel with aluminum fin or copper tubing aluminum fin
  • Heating Exchanger type: Multi-row finned tubing
4.5 Air Recirculating System
  • Hot air circulating duct
    Annular 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 circulation
    The motor is bolted to the rear of the autoclave, it drives the fan directly.
  • Shaft sealing
    Working 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 System
  • 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.
1500X3000mm ASME Certified Electric Heating Rubber Vulcanizer (SN-LHGR1530)

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 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/PED/GB, SINOMAC
  • Hydraulic components: Hualiang, China
Control cabinet according to CE standards

6. System General View (Indirect steam heating)

1500X3000mm ASME Certified Electric Heating Rubber Vulcanizer (SN-LHGR1530)

7. Packing

8.1  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-LHGR1530 VULCANIZATION AUTOCLAVE-TECHNICAL PARAMETER
No. Description Unit Specifications and Parameters
1 Effective Working Diameter mm 1500
2 Effective Working Length mm 3000
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 180
8 Max. Working Temperature ºC 160
9 Temperature Uniformity at Steady State ºC ±1
10 Openning Door Mode --- Hydraulic
11 Working Medium --- Compressed Air
12 Heating Mode --- Electric (Convection+Radiation)
13 Heating Power KW 54
14 Quantity of Circulating Fan Motor Set 1
15 Quantity of Circulating Fan Motor KW 7.5
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 --- Internal
22 Insulation Material --- Ceramic Fiber
23 Insulation Thickness mm 75
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 3260

9. Professional Workshop

1500X3000mm ASME Certified Electric Heating Rubber Vulcanizer (SN-LHGR1530)

From the SINOMAC Team, with 15 years of experience.
1500X3000mm ASME Certified Electric Heating Rubber Vulcanizer (SN-LHGR1530) 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.

1500X3000mm ASME Certified Electric Heating Rubber Vulcanizer (SN-LHGR1530)

2.  SINOMAC Leading Position in the Industry

In order to get high-quality rubber rolls, it is very necessary to directly vulcanize the rubber rolls with metal supports inside. This modified treatment is processed in SINOMAC rubber vulcanization autoclave. Inside the autoclave, the pressure, temperature and time can be controlled effectively without the help of moulds. In this field, SINOMAC has been the leader, as we have accumulated full vulcanization experience and technology for many years.

3. General Feature and Working Process

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
  Temp. setpoint Press. setpoint Temp. step duration Press. step duration
Segment1 T1 P1 t 1 P-t1
Segment2 T2 P2 t 2 P-t2
Segment3 T3 P3 t 3 P-t3
Segment4 T4 P4 t 4 P-t4
Segment5 T5 P5 t 5 Nutrition Porridge Machine

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