Steam Indirect Heating ASME Approved Rubber Vulcanization Autoclave

Product Description

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 Autoclave model: SN-LHGR2560 Effective diameter: 2500mm Effective 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 Capacity Working circle of autoclave: can be set according to the working process Max size of pulley: Ø2000X6000mm 2.3 Electric Power Operating voltage: 400V (AC)±5%, 3 phase, 50 Hz Control power: 220VAC/50Hz/24VDC 2.4 Water, Air and Steam Supply Cooling water consumption: ~4m3/h Cooling water pressure: min.3 bar ~ max. 6 bar Control air of control equipment: 5 ~ 7bar Steam capacity: 2t/h 2.5 Environmental Conditions Max. air temperature: +50ºC Min air temperature: -5ºC Relative Humidity: <80% Altitude: <2000m 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
4. Equipment Technical Details
4.1 Pressure Vessel Pressure vessel with quick-opening door, Design, Manufacture & Inspection: Code ASME Section VIII, Div 1. Shell Material: SA-516 Cap Flange Material: ASTM-105 Forged Shell Flange Material: ASTM-105 Forged Radiography Level: 100% welding radiographic records are included ASME stamping , Nature Of Inspection:a. Review the design drawing and calculation sheet
b. Verification of the material
c. Review welding procedure
d. Review welder qualification
e. Review NDT personnel qualification
f. Review NDT documentation
g. Hydrostatic test 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. Parameters of circulating fan
Power:18.5KW,6-pole, 3phase
Connecting 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 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.
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 Section VIII, Div 1, SINOMAC Hydraulic components: Hualiang, China Control cabinet according to CE standards
6. Equivalency of Standards and Codes
Reference Codes and Standards
6.1 ASME Boiler and Pressure Vessel Code (BPVC), Section VIII, Division 1: Rules for Construction of Pressure Vessels
6.2 AS 1210 - 2010 Pressure Vessels
6.3 AS 4343 - 2005 Pressure Equipment - Hazard Levels
6.4 AS 3873 - 2001 Pressure Equipment - Operation and Maintenance
7. System General View (Indirect steam heating)
8. 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.
9. Autoclave Specification

MODEL SN-LHG2560 VULCANIZATION AUTOCLAVE-TECHNICAL PARAMETER
No.	Description	Unit	Specifications and Parameters
1	Effective Working Diameter	mm	2500
2	Effective Working Length	mm	6000
3	Autoclave Track Distance	mm	900
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	---	Compressed air
12	Heating Mode	---	Steam indirect 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	---	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	---	400VAC, 3P+N+PE, 50/60Hz
28	Weight	KG	16500

10. Professional Workshop
11. 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.