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Rubber compounding equipment Rubber compounding is the process that consumes the most energy in rubber processing. The installed power of a 270 litre mixer is between 1000 and 1500 kilowatts. In recent years, there have been many good experiences in designing new models and increasing the use efficiency.
Dalian Rubber and Plastic Machinery Co., Ltd. studied the internal mixer rotor and developed a variety of new rotors, which greatly improved the mixing efficiency. If the F270 mixer uses the NST rotor developed by the company, the homogeneity of mixing can be improved. The standard deviation of the ODR value of synthetic rubber or tread compound based on natural rubber is reduced by approximately 28% and 69%, respectively. The production capacity increased by about 14% and 10% respectively. Another new structure, the 6WI rotor, is capable of complicating the flow of the compound through a unique design, reducing the coking time by 12%, increasing the filling amount by 1.2%, and increasing the production efficiency by 13%. The national “10th Five-Year†major technical equipment research and development project undertaken by Yiyang Rubber & Plastics Group uses large-capacity meshing GK250E mixers and GK400N mixers with patented technology such as hydraulic top pinning, which not only shortens the mixing time, but also improves the refining process. The quality of the glue extends the service life of the machine. In addition, increasing the rotor speed and pressure of the mixer can also increase production efficiency and save energy. Such as the 270 liters of pressure in a high-speed mixer, when the material pressure ≥ 0.45 MPa, the rotor speed of more than 40 rev / min, each processing 1000 kg of rubber, at least 100 kWh less power than the old mixer. This technology is applicable to the transformation of low-pressure and low-speed internal mixers that are currently widely used in our tire factories.
The use of intelligent mixer control system energy saving is another bright spot for the development of the internal mixer in China. The auxiliary machine series of the amphibious intelligent mixer developed jointly by Qingdao University's soft-control company and Zhejiang University utilizes statistical theory, artificial intelligence and expert systems to solve the fluctuation of mixing quality. After the mixer was used, the dispersity of carbon black was increased by one level or more and the mixing time and energy consumption were reduced by about 7% and 11%, respectively, under the same mixing process and stable raw material quality. In addition, the F270 mixer uses the intelligent control of the MLJ-300 mixer developed by the South China University of Technology, which can increase the mixing efficiency by 20% and increase the rubber pass rate.
The fastest development of tire component preparation and molding equipment extrusion equipment is the pin barrel cold feed extruder, which has many advantages such as energy saving, high output, low glue temperature, and low investment, gradually replacing the hot feed extruder and General cold feed extruder. In recent years, Guilin Rubber Industry Design and Research Institute has developed a three-composite and four-compound extruded tread production line. All of its feed materials are fed with pin barrel cold feed extruders, and the quality and energy-saving effect of the extruded rubber are obvious. The Pin Cold Feed Extruder developed by Inner Mongolia Furte Rubber & Plastics Machinery Co., Ltd. replaced the open mill with other companies such as Anhui Jiatong Tire Co., Ltd., and used it as a glue feeding system for steel wire calenders, reducing production costs by 560 kilowatts for a production line and reducing investment costs. 30% to 40%.
Engineering tire molding has been developed from the traditional fit tread method to a computer profiled extrusion wrapped tread. When Shandong Taishan Tire Co., Ltd. is molding 23.5-25 engineering tires, if the entire tread is pasted synthetically, 4 people can form 7 to 8 tires per class, and when using profile extrusion to form a tread, 3 per class. People can form 12 to 14 tires, the efficiency increased by more than 1 times, the product pass rate increased by 2.5%, significantly reducing production costs.
Hexagonal wire extrusion winding production lines are focused on improving production efficiency. Two-position hexagonal wire ring extrusion twining production lines developed by Tianjin Saixiang and Shanghai Kangxu, which can simultaneously form two hexagonal bead wires, have increased production efficiency by more than 70%. Wuxi First Rubber and Plastics Co., Ltd. cooperated with Bridgestone to produce a 6-position hexagonal wire ring extrusion and winding production line that can simultaneously form 6 wire rings. The production efficiency is at least 4 times that of a single station. Currently, only Bridgestone Huizhou factory.
The radial tire forming machine has developed rapidly in recent years. From the two-drum forming machine to the three-drum to four-drum forming machine, the production efficiency has greatly increased. Tianjin Saixiang, Beijing Aviation Manufacturing Engineering Institute, Guilin Rubber Machinery, Qingdao College Software Control and Shenyang Lanying, etc. Three-drum forming machines can increase output from 50 to 60 tires of two drum machines to 100 to 120 tires. . The four-drum machine of the Beijing Aviation Engineering Institute has a molding efficiency of 130 tires or more.
Tire vulcanization equipment Vulcanization is the main process of steam energy consumption in the tire production process. The first energy saving is through the vulcanizing machine itself, and the second is to promote the new vulcanization process. Among them, the effect of changing the new vulcanization process is more obvious.
Beijing Hezhong Venture Technology Co., Ltd. has developed tire vulcanizers and nitrogen supply systems that are vulcanized with nitrogen, and can provide retrofit services for old machines. It has been successful in several tire factories. Beijing First Tire Company 20 sets of vulcanizing machines have been used for nitrogen vulcanization for one year. They have produced 160,000 tires and added a new production value of 34 million yuan. Chuanchuan Rubber Company of Sichuan Province adopts nitrogen vulcanization in the curing of light-duty bias tires on the basis of nitrogen-vulcanizing radial tires. When this process is used to vulcanize 7.50PR-16PR light-duty bias tires, it can save at least 1.79 yuan per tire after vulcanization without recovering nitrogen. The isobaric variable-temperature vulcanization process developed by Guilin Rubber Machinery Co., Ltd., used to cure 10.00R20 tires, consumed overheated water from the original 5.25 cubic meters per pot to 2.5 cubic meters per pot, and the electric energy consumption was only 30% of the original. In addition, due to the adjustment of the vulcanization process, the tire vulcanization quality can be improved. According to statistics, the isobaric variable temperature vulcanization process can increase tire mileage by 5% to 10% and increase production capacity by 10% to 15%. The process has been promoted by companies such as the Shanghai Truck Tire Factory.
The vulcanizing machine's heating mode is changed from traditional steamer type to hot plate type, which can save about 50% of heat energy. Recently, Guilin Rubber Machinery Factory also adopted the hot plate heating method for Bridgestone's 117-inch large-scale tire vulcanizer, which broke the traditional pattern of hot plate heating that was only applicable to small tire vulcanizers.
Qingdao University of Science and Technology proposed a design scheme for an electric screw type tire vulcanizer. A 63.5" electric spiral tire vulcanizer was developed on the basis of a 42" industrial prototype, and the vulcanized radial tire was tested by the Shandong Rubber Tire Quality Testing Center. Meet the requirements. The consumption of steel and the production cost of the electric spiral tire vulcanizing machine are respectively reduced by 65% ​​and 35% compared with the crankshaft vulcanizer, and by 25% and 65% compared with the hydraulic vulcanizing machine. The machine runs smoothly, is moderately high, and is easy to maintain and test.
The rubber industry is one of the industries with high energy consumption. A traditional enterprise producing 1 million tires per hour consumes about 40 tons of steam per hour and consumes about 7,000 kwh of electricity. In the situation where the price of rubber and other raw materials has increased significantly, the cost of enterprises has increased, and the market competition has become increasingly fierce, energy-saving equipment is increasingly being concerned and adopted by tire companies. China's rubber machinery companies seize the business opportunities brought about by the circular economy of the rubber industry, and proceed with new product development, structural improvement, technological breakthroughs, improvement of production efficiency, and promotion of energy-saving technologies, and vigorously develop energy-efficient rubber machinery and new processes, and promote The rubber industry saves energy, consumes energy, and protects the environment.